Pete (the box slayer) rebuild

Bit of a milestone moment,
Input shaft is fully re-assembled


Just the main shaft left to do when the new PAR gears arrive.....

I'm not going to lie.....I've just touched myself

The new gears and seal's will be with you Friday night hand delivered

This build is getting a little bit sexual ! Lol

Yep a bit of alone time for Pete with a box of tissues

Did you sort out the size issue neil ?

nomad wrote:Did you sort out the size issue neil ?

He just had to use a little bit of spit and gave it a good rub and it soon came to size

shroom wrote:

nomad wrote:Did you sort out the size issue neil ?

He just had to use a little bit of spit and gave it a good rub and it soon came to size

Haha, i just need to look at your sexy profile pic to get the steam snorting out my nostrils like a randy bull.

nomad wrote:Did you sort out the size issue neil ?

No we didn't Leighton. PAR didn't get back me so Pete's got no choice but to like or lump it.
The 0.5mm issue isn't a show stopper because it didn't effect the actual gear, but it's welded snychro-plate on the side.
All it really means is that Pete has an extra 0.5mm of shift travel in that gear.

The new PAR gears I'm not even going to measure what's the point? what can we do if they're also out?
But as long as it shifts without clashing, everything is clinically clean and the bearing clearances are done properly it should be fine (touch wood   )

TBH the support from PAR has been crap and i don't think Pete is their biggest fan either now.

Trouble is there gear's are good and well tested they won't give support as most people will ring them and say your advice is wrong my box blew up. Every box and tolerance is different on so many components there prob is no right or wrong advice unless it's infront of them

There customer support is id personally say almost non existent, also taking money not just from myself but anther person I know, promising a delivery date and not even posting them out! Also very good at not responding to emails if you have any sort or issue which then I have to ring Australia! I wouldn't usually say anything on a public forum but there 'customer service' is utter shite!

^ interesting to know. I also contacted PPG about some stuff and never got a response. Bastard australians!

Yeah I had just same with ppg, par was okay on phone discussion on Subaru info. Why they don't have a spec PDF for each kit online is beyond me !

I contacted PPG too about there clutch forks! Never had a response either. PAR did reply so I bought from them, although I must say the finish on them is far from what I expected, I think the 40 grit sand paper is as well finished!! Good job they were cheap..... Cough!!

Its all the sun and shit beer its puddles their brains. They are so laid back lol

Hey Pete,
I found my post about trying to remove that diff bearing (scroll about half way down)
http://www.gtir-motorsport-club.com/t6138-bearing-removal-and-fitting-kits

you can see why i ended up leaving it on as it was in good nick, which isnt option because of your pitted one
But at least i already have a new replacement

Cosmic73 wrote:Hey Pete,
I found my post about trying to remove that diff bearing (scroll about half way down)
http://www.gtir-motorsport-club.com/t6138-bearing-removal-and-fitting-kits

you can see why i ended up leaving it on as it was in good nick, which isnt option because of your pitted one
But at least i already have a new replacement

Yep just had a look, perhaps grinding it off is the only option?
Also if you can't find the new gaiter ask your lad if he's put it I the vase ...man that made me laugh

Use a bearing separator clamp.
Cut the cage off bearing (screw driver & side cutters)
Use the bearing separator clamp on the lip of the inner bearing race (use flat edge of clamp not tapered)
now either use extensions & puller on the clamp or mount in press .
You can buy half decent versatile bearing separator clamp full kits for around £60 & just a large clamp for about £25
I done this a few times on diff side bearings & pinion shaft bearings.
Better tool is clam-shell kit as can remove saving bearing but they expensive & in most scenarios you replacing bearing .
Google should produce videos on this as methods used a lot on diffs .
cosmic got tools at work fir this (same puller he used on mainshaft)

mightydquinn wrote:I contacted PPG too about there clutch forks! Never had a response either. PAR did reply so I bought from them, although I must say the finish on them is far from what I expected, I think the 40 grit sand paper is as well finished!! Good job they were cheap..... Cough!!

Did you use the online inquiry form? Ive noticed alot of company are terrible with replying when you submit a question through an online form. I always seem to get responses when I send a direct email.

Mr B wrote:Use a bearing separator clamp.
Cut the cage off bearing (screw driver & side cutters)
Use the bearing separator clamp on the lip of the inner bearing race (use flat edge of clamp not tapered)
now either use extensions & puller on the clamp or mount in press .
You can buy half decent versatile bearing separator clamp full kits for around £60 & just a large clamp for about £25
I done this a few times on diff side bearings & pinion shaft bearings.
Better tool is clam-shell kit as can remove saving bearing but they expensive & in most scenarios you replacing bearing .
Google should produce videos on this as methods used a lot on diffs .
cosmic got tools at work fir this (same puller he used on mainshaft)

I see what you mean now, yes that would save grinding the race.
We have these seperators at work so i could do this during my lunch,

^ extended lunch I hope .
Have 2hr+ lunches here quite regularly :-)

Mr B wrote:^ extended lunch I hope .
Have 2hr+ lunches here quite regularly :-)

Rub it in why dont you,
I barely get time to bite a sarnie and slurp a brew

That sucks ... things here are very laid back on time management lol . with coffee & small food stalls everywhere around company work areas it a struggle fit work into the time schedule :-D

2nd major milestone complete,
I've just finished assembling the mainshaft assembly with the new 1st & 2nd gears, new bearings and uber-clean parts,    


Bit of disappointing news about the diff however.
I have a spare LH bearing, but the RH bearing can't be collected from Nissan till the 20th September!!  

So close yet so far! Looking good

Looking good!
Its not going to hurt waiting a little longer now it's all coming together. Atleast the end is in sight.
Great work Neil.