gearbox/cutch issuse - loose fittign clutch splines

[Disturbed1]

ive been having quiet a few problems with my tko 500 gearbox...mainly excessive noise and 3rd gear crunching

it is currently stripped back looking for possible causes to high rpm shifting problems.

malwood who specialise in these boxes say there is so many variables its not funny. so im kind of stumped, as in their ideal world - id need to send the whole car to them for them to dianose it

everything from bellhousing/spigot allignment to within 2 thou, to tailshaft angle to bearing preload to numerous clutch related issues like clutch float and drag all the way to shift technique.


they tell me they have 800 hp cars and 9 sec rotaries running these boxes yet when he asked what my rev limit is and i replied 7k. he said "that is extremely high rpms and for your box to shift at those kinda revs - everything will have to be setup perfectly" (fuck knows what their drag rotary revs out to then)

so yeah

the gearbox joint that has looked over my box (since my 2 failed attempts at just swapping syncors) recons the 3/4 hub is fine, as with the recently replaced syncro however the gear the syncro mates with is still highly glazed and that there is slight wear on the "synco teeth or whatever u call it - not the brass blocker ring and not he actual gear driving surface but where the hub enguages) which isnt excessive so nothing to worry about.

one of my concerns which he doesnt seem too worried about himself is the large amounts of play off the clutch plates on the input shaft. although u can see a marked portion on the input shaft where both of the solid centred clutch discs have been sitting, their doesnt appear to be any wear on either componants - just a real sloppy fit. enough to wobble (not twist) the clutch plate back and forth about 10mm. given the centre splines on the clutches are 14mm deep - i find this amount of play abnormal but have no experience myself. BTW im runnign a 10 spline ford input shaft.

question is - could this excessive play be causing any dramas when im tryign to change gears at 7000 rpm??

if so ill just buy a new 26 spline input shaft and swap the centres on the clutch to accomodate.

if theres any other comments or suggestions fire away - the more the merrier

cheers

[The Real Roadrunner]

question is - could this excessive play be causing any dramas when im tryign to change gears at 7000 rpm??

if so ill just buy a new 26 spline input shaft and swap the centres on the clutch to accomodate.

if theres any other comments or suggestions fire away - the more the merrier

cheers

The play may be causing issues but its more likely to be the centre plate in the clutch not disengaging fast enough, ie grooved / worn posts or cage assembly.

i would swap to the 26 spline shaft as they are potentially alot stronger (if made correctly) and at the same time change to sprung centre's as i feel they shift better allround not to mention the reduction in chatter through the driveline (been there done that, my ears are still ringing).

cheers
linden

[Disturbed1]

would the fact im only having issues with 3rd gear suggest it might not be clutch related??

granted ive never gone for any crazy 2nd gear shifts and the semi firm ones dont seem to let u wanna change quickly so just let it do its own thing.

never had any problem 3rd to 4th no matter how hard i try

and i think the gate into 5th isnt the best as its very hard to go 4-5 fast. is like a two step procedure (ie back to neutral then over and up into 5th in 2 steps)

the clutch is an os giken twin plate with custom centre plates. the fingers on the plate do seem to have a substantial amount of wear on them though from the release bearing

[Disturbed1]

http://www.youtube.com/watch?v=_2jeX...e=channel_page

here is a youtube link of the clutch splines

[BlackSupra]

i cant remember exactly, but im sure my plates had less play than that on the shaft.

[skiddz]

http://www.youtube.com/watch?v=Xz7Yu...eature=channel

i like that video better