Gearbox outer case assembly Clearance

Status
Not open for further replies.
Samuel Whittle

Samuel Whittle

Joined
Apr 15, 2020
Messages
13
Country flag
Hi everyone,

I am reassembling an outer gearbox cover on a 72 Commando. The old one fits fine but was all banged up so I ordered a new one from Andover Norton, I know the assembly was exactly as before but now it is not clearing the clutch cable lever (it was before). Could the outer gearbox cover I got be shallower?

Gearbox outer case assembly Clearance


I was also surprised to see he amount of inconsistency between the old inner and new outer casings. Old one appears to be quite wider in some areas. They don't match perfectly...

Gearbox outer case assembly Clearance
 
Last edited:
You might have to do some minor shaving of either the lever or case. Sometimes they are very close. I have not seen a new case.
 
seattle##gs said:
You might have to do some minor shaving of either the lever or case. Sometimes they are very close. I have not seen a new case.
Click to expand...
At the point where the clutch lever rubs, the new case is 4mm shallower than the older one...that seems like a lot to be different!
 
Samuel Whittle said:
I am reassembling an outer gearbox cover on a 72 Commando. The old one fits fine but was all banged up so I ordered a new one from Andover Norton, I know the assembly was exactly as before but now it is not clearing the clutch cable lever (it was before). Could the outer gearbox cover I got be shallower?

Gearbox outer case assembly Clearance
Click to expand...

If that's the new cover then I can't see where the problem is when compared to my own, below?
Gearbox outer case assembly Clearance
 
Maybe it's the picture but the cable angle doesn't look right.
Could be the cable boss on the new cover is slightly different than the old cover which results in a different cable angle.
May have to realign the adjuster with the new cover, which may give more clearance.
 
MichaelB said:
Maybe it's the picture but the cable angle doesn't look right.
Could be the cable boss on the new cover is slightly different than the old cover which results in a different cable angle.
May have to realign the adjuster with the new cover, which may give more clearance.
Click to expand...
Do you happen to have an example of what you mean when you say, "the cable angle doesn't look right". What would you expect it to look like? I am no expert which is why I was hoping the photos might help to spark some ideas!
 
The adjuster fork should line up with the cable boss.
It looks like the cable pulls to the right, which means the adjuster needs to be clocked left a little.
With the cover still on, make a mark with a Sharpie on the inner cover where the cable boss is.
Remove the cover and see if the fork lines up with the mark, adjust accordingly.
BTW, this usually doesn't affect the install of the cover, just the operation of the clutch.
Maybe your cover is shallower. Would be interesting if you could take some measurements and compare.
 
MichaelB said:
The adjuster fork should line up with the cable boss.
It looks like the cable pulls to the right, which means the adjuster needs to be clocked left a little.
With the cover still on, make a mark with a Sharpie on the inner cover where the cable boss is.
Remove the cover and see if the fork lines up with the mark, adjust accordingly.
BTW, this usually doesn't affect the install of the cover, just the operation of the clutch.
Maybe your cover is shallower. Would be interesting if you could take some measurements and compare.
Click to expand...
Okay, I will give that a shot. Well like I said, where the clutch lever fouls out, it is almost 4mm shallower. Thats a lot....I mean I could certainly shave some out and maybe cut 1 mm off the clutch lever but this is an Andover norton product. Thats seems pretty far off, doesn't it? https://andover-norton.co.uk/en/shop-details/15392/gearbox-outer-cover-assy
 
Samuel Whittle said:
Do you happen to have an example of what you mean when you say, "the cable angle doesn't look right". What would you expect it to look like? I am no expert which is why I was hoping the photos might help to spark some ideas!
Click to expand...
The cable should be straight - it looks like the actuator is too far clockwise by a good bit.
 
marshg246 said:
The cable should be straight - it looks like the actuator is too far clockwise by a good bit.
Click to expand...
Re-align the arm to cable pull where it is a straight pull and is happiest. Tightening up the big ring can set alignment things off so double check the final cable pull path. Never seen a new AN outer cover. I put a dab of grease to the cable end here seeing as lubrication upper outer cover is somewhat lacking.
 
The cable does look way to the right. It is very importand to have it lined up dead on with the cable entrance point on the inner cover. Any little bit off makes for a noticeable harder pull. Sometimes it takes several attempts to get it right but you must do it.
As for clearence you might try a second gasket. I have never tried that
 
seattle##gs said:
The cable does look way to the right. It is very importand to have it lined up dead on with the cable entrance point on the inner cover. Any little bit off makes for a noticeable harder pull. Sometimes it takes several attempts to get it right but you must do it.
As for clearence you might try a second gasket. I have never tried that
Click to expand...
I use a peen punch into the soft aluminum inner case , and when the arm and cable locates for a straight pull, I tap it to mark for the future. Because there will always be the future.
 
Daft question (my forte)... But is this assembly 'loaded' from the rear: I.e: Is there pressure on the actuating arm from the pushrod as if the clutch was assembled?
Only ask as the arm won't travel in the correct arc without it....
 
MichaelB said:
The adjuster fork should line up with the cable boss.
It looks like the cable pulls to the right, which means the adjuster needs to be clocked left a little.
With the cover still on, make a mark with a Sharpie on the inner cover where the cable boss is.
Remove the cover and see if the fork lines up with the mark, adjust accordingly.
BTW, this usually doesn't affect the install of the cover, just the operation of the clutch.
Maybe your cover is shallower. Would be interesting if you could take some measurements and compare.
Click to expand...
I have two (old ) versions of the outer cover for that box, one of which is not interchangeable with the other. ( probably pre Commando).
 
With my new cover the arm was touching.... with the old cover it wasn't Mr. Dremel soon sorted it
AN weren't aware of any issues with the batch of covers and to be fair did offer to replace
With all the posit hassle & lockdown i couldn't be asked to send it back
 
olympus said:
With my new cover the arm was touching.... with the old cover it wasn't Mr. Dremel soon sorted it
AN weren't aware of any issues with the batch of covers and to be fair did offer to replace
With all the posit hassle & lockdown i couldn't be asked to send it back
Click to expand...
Glad it wasn’t just me. So yours too was considerably shallower but you just shaved out the inside? Okay I may just go that route then. Thanks!
 
I really sure that if you correct the alignment of the cable that you'll have no issue with the cover and will improve the clutch action . The arm will be in the inspection hole and won't be close to anything. It is easier to do with the correct tool. Promise to send it back and I'll send you one.
 
marshg246 said:
I really sure that if you correct the alignment of the cable that you'll have no issue with the cover and will improve the clutch action . The arm will be in the inspection hole and won't be close to anything. It is easier to do with the correct tool. Promise to send it back and I'll send you one.
Click to expand...
I went back this morning to take a look after everyone responded and it was just a really deceiving photo. It appears to be dead on to me.
Gearbox outer case assembly Clearance

As for the case being to shallow. I guess I will need to shave it. This is the state at which it fouls out and has about 3mm left to go.
Gearbox outer case assembly Clearance
Gearbox outer case assembly Clearance
 
Samuel Whittle said:
I went back this morning to take a look after everyone responded and it was just a really deceiving photo. It appears to be dead on to me.
Gearbox outer case assembly Clearance

As for the case being to shallow. I guess I will need to shave it. This is the state at which it fouls out and has about 3mm left to go.
Gearbox outer case assembly Clearance
Gearbox outer case assembly Clearance
Click to expand...
You're there so I'm not saying your wrong, but I still think it is wrong. The way to tell for sure is the mark the inner cover where the cable enters the outer cover. Remove the outer cover and the actuator arm. Then using a flat piece of metal against the inside of the slot the actuator rides in, see how you line up. If that's right, the other possibility is that the rod, ball and actuator are not properly engage and the actuator is too low - it seems a little low in the picture. I realize it worked with the old cover but there are a lot of variables - rod adjustment, cable hole angle, cable hole placement, inspection hole placement, and of course, the wall thickness you are thinking about. My concern is that you have a long way to go to get the cover on and I've replaced them without any trouble.
 
Status
Not open for further replies.
Back
Top