I have a 3-speed crash box previously converted to 'Rolt Ulster' ratios. Although I haven't yet used it, sitting on the shelf it became increasingly stiff to turn, despite being well covered in oil. On inspection, I discovered that it was the layshaft that is sticking, since first and third motion shafts turned fine in neutral. I also found that by slackening the rear cover very slightly, the box would ease up and function fine. I thus presume that by either removing a shim from the layshaft or adding a thicker gasket to the rear cover all will be well.

I have therefore followed Woodrow's dismantling method, but hit a problem removing the third motion shaft/rear cover. When I tap the spider nothing happens (much). The rear cover is free, but the shaft stays put. I can't see how to get a puller on it. What to do? Heat?

John

John,

Heat with a hot air gun or similar as Charles says. I have made a slide hammer with a plate to bolt on the 3rd motion shaft which makes the whole job very easy.

If you are going to make a slide hammer it is worth making adaptions for pulling out rear spring pins and king pins too.

R

Thanks both -that's helpful, Woodrow makes it sound very easy, so I am now reassured that it is 'normal' to take a little more effort. I think I will dismantle, just to find out the cause -much easier now than when fitted to the car.

Worked like a dream. Normal service resumed!