Struggling with second gear...
Turbo Mini Forums

Trying to get second gear of the third motion shaft and having no success at all.

The haines book if lies says to line up the holes in the gear with the pins and the slit in the retaining ring and you should be able to depress the plungers and rotate the ring.

I can't find the holes. I've looked through the holes in the gear the full circumference of the gear and can't see any kind of hole or recess to put the pins through.

Have tried depressing the pins by levering the pins into the shaft and rotating the ring, but it gets to a knat's cock from the right place then just pings round and of the pins. Pretty soon I'm going to throw the shaft at something - probably John for breaking the gear in the first place!

What am I doing wrong?

Without special tools, it just takes patience.

There are no holes on the gear that I've ever seen.

I can't remember if it is 2nd or 3rd - one has a single plunger , the other two plungers - but in both cases I ground up a pair of TIG tungstens (really hard so don't bend) to depress them then rotated the ring with the tip of a centre punch.

Really needs three hands for the gear with two plungers :)

It is tricky though, so don't give up.

Schrödinger's cat - so which one am I ???

ive just watched this http://www.youtube.com/watch?v=eeQ0OeEL1BY...46fAHTygxYwAAAA
which shows it has 2 plungers and says there's holes in the 2nd gear.

one day boost will be mine!

Rod - it's second that has the two plungers. There are 2 holes in the cone bit of the gear about 160 - 170 degrees out.

Looking at the pic's in GW's video they are on the inner face of the ring so no point trying them when removing. That explains one thing at least. Can't see why haines say to depress them there id there's no way to get it through...

Back to a bloody cold garage...

sorry Andy for all the trouble

Done now needs redoing lol

the holes in the gear only aid the build up iirc, to strip down you need to push the 2 plungers at the same time with a pointy object, and twist the retaining ring slightly to hold the plungers in, then the gear retaining ring should slide up

my tip is if you look closely at the retainer ring you should see one gap is bigger than the other, if you push the plunger with the SMALLER gap in first you can rotate the retainer ring enough to hold one plunger, the same again with the second plunger
point object of choice 0.8mm welding wire with abit bent over so not to stab your self

Edit: too slow

Edited by Brett on 31st Jan, 2012.

Yes i moved to the darkside

Instagram @jdm_brett

the holes in 2nd gear synchro cone are for re assembly.

You need to use a small thin screw driver that is string enough to slide down between the pin and the lock ring, then rotate the lock ring and then repeat on the second pin. Carefull when rotating the lock ring for the second stage as if you turn it too far, you'll be back to square one

Has to be fixed who ever has the box Curt, don't worry about it.

Brett, Sprocket - That's exactly what I'm doing with tiny flat screw drivers. It just seems to need that much force to move it the last 1-2mm it just pings round and back of the pegs. I guess it's just perseverance...

Just looked at some of my old photos... the holes in the gear may help re-assembling - but have nothing to do with dismantling.

The plungers are inside the ring when assembled so need to be pushed down from the side (or "end"), not from "above", so not through any holes in the gear.

I think that is what you are seeing yourself.

EDIT - too slow...

Edited by Rod S on 31st Jan, 2012.

Schrödinger's cat - so which one am I ???

Finally got it of!!!!

For anybody else trying this, I found it easier to sit the shaft in a vice so that second gear was resting on the jaws (third gear at the bottom). Once the pins are retracted and held by the ring. Hold the ring with a screw driver in the groove and rotate the shaft with your other hand. This proved more controlled than the other way round.

Once I'd got it lined up a very gentle tap with a rubber mallet on the end of the shaft saw the ring and gear slide of a touch. Then the gear just lifted of. In my case, second gear is fooked, so I don't care if I damage it further.

you should have brought it over andy

thanks for the offer Steve.