Gear plate question?????

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grfilipp

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my tt since day one has a problem that i cannot solve. melting gears.


i tried all the tricks(cover no cover cover with holes.....metal gears).


i have spent a lot of time and money on gears and it is the only thing that i find annoying with the car. it is such a problem that i am thinking to just give up on the car.


i ended up on the conclusion that both my carriers (v1,v2) are not correct.


as you can see on the pics the distance that i have is


29-31 52.85-7.97=44.88mm


25-25 44.79-7.97=36.82mm


if i am correct the gears are module 1.5 and if my calcs are correct the shafts should be


29-31 45mm


25-25 37.5mm


i know that i might not measure 100% but i really believe that the shafts are too close. with plastic gears i get away with it for a bit but when i installed my metal gears the car was not rolling at all after insisting, some voices were talking about breaking them in, they just got destroyed.


can someone please help???


measurement of your gear plate or any ideas on my calculations anything. i am really stuck with this problem.


cheers


IMG_0466.webp


IMG_0465.webp


IMG_0464.webp
 
i did and it make no difference.


it is impossible to install metal gears no matter what bearings they just bind.
 
Try this, and im grasping for straws with this one. Remove your gearplate from the car and install all the bearings, gears, clutchbell and layshaft. Hopefully everything will spin freely. What im thinking is a hole could be misaligned applying pressure to the gearplate causing it to bind up.
 
I went with mcds 23/26 no binding . i found that my shafts on one gear plate was 3tho diferent than another .but with the mcds now binding.
 
the hole is definitely misaligned and i believe it is the middle shaft one. that is why i asked if someone that does not have a problem with melting gears could measure the distances.


the shafts have not problem spinning. when i try to install the gears is the problem. when i install plastic ones it is ok after running them a bit but metal ones is is pain even to put them on the car. after that the car is like it has breaks full on.


i tried plastic mcd gears but did not last at all. metal ones is not something i want to do as they are the wrong size to begin with and not the cheapest option to experiment on.
 
Obeast44 said:
Try this, and im grasping for straws with this one. Remove your gearplate from the car and install all the bearings, gears, clutchbell and layshaft. Hopefully everything will spin freely. What im thinking is a hole could be misaligned applying pressure to the gearplate causing it to bind up.
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reading again what you wrote realized i got it wrong.


well i had a thought about it and i took everything apart to check what is going on. i fount the pinion bearing in bits and pieces. i do not know if that was the cause or the result but i will soon find out. the other thing is that i have a zen engine since day one and i wonder if the hole i made for the engine was some how creating stress on the gear plate and as a result the gear failure.


i will know soon more after some testing is done.
 
does your gear plate have the aluminum insert in the back, if so unload it and buy one of the v1 versions, the gap between clutch and spur are off. thats why i have a few v1 spares.
 
rob64n said:
does your gear plate have the aluminum insert in the back, if so unload it and buy one of the v1 versions, the gap between clutch and spur are off. thats why i have a few v1 spares.
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i got both carriers.


i had the same problem with both.


i am working in a custom solution to try since i cannot get the metal hub in Australia.


i believe i will have some photos and news tomorrow.


btw thanks everyone for the input
 
I run a Zen on mine without problems, just make sure you tighten the gearplate bolts to the engine first then put the ones up through the bottom of the chassis. If the bottom 2 screws don't start threading easily they can put stress on the gearplate. Causing it to flex, creating the gear mesh issues.
 
i tend to believe this is what caused my problems all this time cause i never used the stock engine and although the carrier might be off it cannot be only me that would have that problem.


what i am working on is a shaft that will go as a press fit on the pinion to make sure everything aligns perfect. then i will be able to check where the bind is coming from (no engine installed).
 
Try assembling the entire drivetrain on table, thats engine ,gearplate, layshaft and center spool. Everything should roll freely. If it does, drop the entire unit onto the chassis and start each screw a few threads deep, and check for binds. Then start tightening 1 screw at a time and check for binding after each one. You will eventually find the problem.
 
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