Stuck in gear

[RafM]

I'm getting towards the end of a restoration on my 1972 TC, 365-5sp gearbox.

The PO had already done most of the mechanical rebuilding/overhaul. I've had the car running and driven up and down the drive a few times, all seemed in order bar
some adjustments needed. The indent ball and spring were not fitted but the shift worked very well, selecting all gears easily.

The problems have started since fitting the ball and spring and trying to adjust for rev & 5th indent. The cam just jams against the ball when trying to shift into 5th or rev,
it won't push it back against the spring. I'm not too keen on this set-up anyway and was likely going to make a lift up type of mod on the gear lever, something that I've seen well
documented on other threads.

However, the car is now stuck in a forward gear and I'm pretty sure a selector fork is the problem. Well described in this thread.

http://www.lotuseuropa.org/LotusForum/index.php?topic=2147.msg20076#msg20076

Does anyone have any tips regarding the removal of the rear housing with the gearbox still in situ? it's a tight fit against the rear cross-member hoop but I'm hoping it's possible to tilt
the engine/gearbox to give access.

Thanks, Raf.

[BDA]

I don’t have a 365 and I had pretty much said all I could in that thread. Europa73 didn’t say it was resolved. You might try sending him an email (click on the envelope under his avatar) or send him a PM to see how he solved it.

[jbcollier]

You should be able to tilt the transaxle enough to get the rear cover off, no problem.

[4129R]

If you tilt the engine and gearbox, the hose will come off the water pump.

Loosen the clip where it joins the pump, and reconnect when the gearbox is back level with the 2 rear mounting bolts in position.

[RafM]

Thanks for the replies, good info re hoses etc.

I'll have a look and post up when I find what the issue is.

[Kendo]

I don't know if this applies to your situation, or if you really have an internal jam. But when I got my TCS last century, I had the same problems shifting. I ended up filing the ramp slightly on the cam to ease it's introduction to the ball. It doesn't take much, so if you go this way, take it slowly. Also, for some reason the ramp for reverse was different than for 5th.

[RafM]

I don't know if this applies to your situation, or if you really have an internal jam. But when I got my TCS last century, I had the same problems shifting. I ended up filing the ramp slightly on the cam to ease it's introduction to the ball. It doesn't take much, so if you go this way, take it slowly. Also, for some reason the ramp for reverse was different than for 5th.

It's definitely stuck in gear but I came to the same conclusion regarding the angle of the indent ramp. It needs filing down a bit to make the action smoother (or work at all) Another Lotus solution
which is not a bad idea but poorly engineered.

[TCS4605R]

Did you have the rear cover off?  Is the gearbox stuck in two gears, thus locked up?  The 4th gear detent ball may have fallen out of its hole and dropped into the gearbox housing.  Before you remove the rear cover, you need to engage 4th gear - this keeps the detent ball in its proper place as you remove the rear cover - or am I not understanding your problem?  I've made this mistake and have been able to fish the detent ball out of the gearbox with a pickup magnet.

Tom
74 TCS - 4605R

[RafM]

Did you have the rear cover off?  Is the gearbox stuck in two gears, thus locked up?  The 4th gear detent ball may have fallen out of its hole and dropped into the gearbox housing.  Before you remove the rear cover, you need to engage 4th gear - this keeps the detent ball in its proper place as you remove the rear cover - or am I not understanding your problem?  I've made this mistake and have been able to fish the detent ball out of the gearbox with a pickup magnet.

Tom
74 TCS - 4605R

Hi Tom,

It's stuck in gear but not locked up, I'll try and engage 4th before I remove the cover, the main selector shaft appears to be moving, thanks.

[4129R]

Where in the UK are you?

I took a gearbox out and repaired it recently.

They are easier than you expect to work on, once all the smelly oil is drained out.

[RafM]

Where in the UK are you?

I took a gearbox out and repaired it recently.

They are easier than you expect to work on, once all the smelly oil is drained out.

I'm not far from M25-J6. I don't expect too many problems unless some obscure part is required.

[RafM]

I decided to take the entire gearbox out and check everything thoroughly.

So far I've taken the end cover off, the 5th gear selector fork came out with the cover, the 5th gear syncro hub nut
is finger tight and so is the speedo drive nut. There are no keys or springs in the 5th gear syncro as shown in the workshop manual.

Doesn't seem right to me....

[jbcollier]

Definitely a good idea to completely strip the transaxle if you found those problems.  There are a few parts in the 365 that are pure unobtainium.  One of the them is 5th gear.  If yours is in good shape, count yourself lucky.

[RafM]

Stripped the box down and found these pieces in the diff housing area, seem to be only half of what's broken but can't see any other
pieces anywhere.

Possibly a part listed as a 'stop washer' which are on the primary shaft?

Next question is where to get any replacements, 5th gear is in good condition but seems to be missing the 3 keys and syncro spring.
Any advise gratefully received.

[BDA]

You might call Michel at Alpine-America (http://www.alpine-america.qc.ca/). He normally takes vacation in October and gets back in May (IIRC) but he may answer his email. He has a lot of experience with both Europas and Renault. You might also try Meca Parts (https://www.mecaparts.com/) which is a Renault parts supplier.