Misaligned engine and gearbox

Previously wrote:

Hi folks, I am half way through my Mk3 rebuildnow and I have encountered a problem which has bamboozled me. The gearchange cross-shaft from gearbox to primary chaincase seems to point too far forwards and the chaincase cover can't now go on. I have slackened all carrier bolts on the engine and the two gearbox bolts/studs but, although they float a little bit they won't line up.

The shaft is straight, I've rolled it on a flat surface to prove it. All I have done to the frame is to have it powder coated and, although the job was rubbish (I had it done in Birkenhead, be warned...), there doesn't seem to be any damage.

Has anyone come across such a phenomenon before?

Thanks for listening.

i can make an uneducated guess that maybe the engine to gearbox plates may haveexchanged sides if that is possible as i think the shaft mustpass through them both ?, but dont rush to strip it down until a mk 3 owner / expert agrees , good luck .

Previously wrote:

Previously wrote:

Hi folks, I am half way through my Mk3 rebuildnow and I have encountered a problem which has bamboozled me. The gearchange cross-shaft from gearbox to primary chaincase seems to point too far forwards and the chaincase cover can't now go on. I have slackened all carrier bolts on the engine and the two gearbox bolts/studs but, although they float a little bit they won't line up.

The shaft is straight, I've rolled it on a flat surface to prove it. All I have done to the frame is to have it powder coated and, although the job was rubbish (I had it done in Birkenhead, be warned...), there doesn't seem to be any damage.

Has anyone come across such a phenomenon before?

Thanks for listening.

i can make an uneducated guess that maybe the engine to gearbox plates may haveexchanged sides if that is possible as i think the shaft mustpass through them both ?, but dont rush to strip it down until a mk 3 owner / expert agrees , good luck .

Thanks for that Adrian, unfortunately one cannnot get that wrong, the plates are all welded together and form the rear isolastic link to the frame. The gearbox sits in this welded framework and attaches to the rear of the engine by three bolts. It seems so very odd that it doesn't line up, I might have to strip it all out again and get the measuring instruments out.

Previously wrote:

Peter, make sure that you haven't forgotten the spacer on the top gearbox mount (1/8" or so). The lack of this can throw things over quite a lot.

The crossover shaft is angled slightly forwards, presumably to clear the quadrant fixing (which they had to change from screw to circlip in order to gain some space). It should pass roughly centrally through the aperture in the drive side engine plate.

There is normally a bit of play in the shaft itself. If you're central in the inner chaincase oil seal then the problem must lie with the outer cover. Have you replaced the small bush or the pedal bushing ?

Richard, I think you've hit the nail on the head. I have omitted the spacer... I presume it goes between gearbox and the inner face of the plate - on the right hand side is it?

Haven't touched the chaincase, so it must be the spacer.

The guru strikes again it seems... Thanks Richard.