Cougar Sv layshaft
 

Is it a good idea to glue in the needle pins to the layshaft before putting the o rings on. I ask because my first gearbox shredded when a pin came out!

i wouldnt

Could you use roll pins instead of the solid pin? A good tight fitting one? Saw a couple of cars had these pins coming out at the weekend. Mine seems fine so far. Not sure why these were coming out. Any ideas?

Where trying a thicker o ring.

My theory is that the original o rings are too soft and expand too much under the centrifugal force generated by the fast rotation hence the ring comes off or, expands sufficiently to allow the pin to fall out. Not 100% sure though.

Why not Carl? Fair play to schuey for replacing my damaged parts this time ( which suggests to me that they know this could be an issue) but I doubt they would keep replacing parts in these circumstances.

what happens when you need to remove them, check pin edges make sure there smooth (rounded of )

The first pins I had were fine and so are the replacement pins I have. Was thinking of using loctite retaining compound which I have experience with in other applications at work. This would defo hold the pin during running but one sharp tap of a pin punch would release it if necessary.

Steveb has had this issue too. So they replaced what bits?

Idler gear, layshaft gear, 2 pins, 2 o rings, diff gear and gear box casings. Spoke direct to PB and he agreed to do this.

What I have used and let all US drivers in on is a external snap ring size of 7/16". It looks like the ring for the thrust bearing, but the ears face out, and obviously larger.

do you have a pic of the o-ring Raul?

http://out2win.com/catalog/images/snapring.jpg

They're also known as circlips.

Thanks again Raul.

I have had both o rings let go both with no damage, I had to run it for a race with all the o ring debris still there and no o ring. The originals are smaller than the replacement ones I have fitted thus they where under stress to start with.

Have emailed Schumacher this morning and will go from there.

SteveB if he gets time (work pressures) will prob call Phil at Schumacher.

Thanks for the pic Lamar.

Who makes these?

I'll be taking mine apart tonight and expect it to be the same :(

i think a better question would be to ask why there are drive pins inside the gearbox at all. i am sorry to say that, in my opinion, its a really poor design especially when there is potential for them coming loose and wrecking the gears. its a pity they didn't copy the B4/X6 gearbox style for this car - funnily enough there are no drive pins in those gearboxes - its almost like they knew what they were doing :woot::woot:

on second thoughts, maybe they will just fall out of the gap at the rear of the gearbox before causing any damage !

I have wonder why the layshaft isn't one piece...

lol

It'd make a lot more sense,and are people really going to be changing the internal ratio that often? It'd still make more sense to just swap layshafts instead of disassemble/reassemble.

You don't change the layshaft anyway for changing gearing I think, that's done outside the gearbox..

The layshaft and idler internally are not changed to alter ratio, this is done by changing the 2 gears external to the box ( see manual for reference). There is no reason why the internal part of the layshaft can't be 1 piece IMO.

I'm going to glue the pins.
Like this I'm sure they don't come out and anymore!

I had this happening last weekend and the day was finished for me.

Exactly, I'm with you on this. I think schuey need to look at this design judging by the amount of people experiencing this problem. Come on Schuey give us a factory designed and tested fix!

cat sx has run this kind of idea for years without problems guys??

not in a 'sealed' gearbox though. and the fact that it has been used on the SX doesn't make it acceptable in this instance

I just pulled my gearbox apart and my pins had moved a little, an o-ring was slightly raised, and it had been rubbing very slightly.

I've chosen to threadlock the pins in.

Wise choice I think, what's the worst that can happen, I can't see a reason for needing to remove the layshaft gear anyway.

I guess my suggestion is not worth as much to the uk drivers as it was directly to the engineer @ Schumacher...

Phil did mention it today when I spoke to him...

I havn't had any issues yet but ive only used the car for one race meeting .. Yesterday i dropped in on a automotive shop and grabbed a couple of these 7/16" snap rings and will be installing them very soon prior to my next meeting.

Cheers for the tip Raul..

Good idea but I personally don't want to add another metal bit that could potentially cause damage in a sealed gearbox although it is very unlikely.

Smart man...

Need to look into this too, but I'm in the UK.

Is this the sort of thing?

http://simplybearings.co.uk/shop/pro...ducts_id=21863

This is what it looks like it's 7/16".

If you need them I can get them, we use all American size stuff at work for our US built machines. Let me know if you need them and I can find out who our supplier is.

although i wouldn't fit one myself, if you want to try it, here is a link :-

http://www.modelfixings.co.uk/circlips.htm

you can get plenty of internal circlip spares while you're at it for rebuilding the diffs with their (un)user-friendly design of thrust race retention (and yes, i know the design was used in the CAT SX plus i remember them in my Axis TC from years ago - they were crap then too)

Not had a problem with my SX or SV..

this happened to a couple of cars at the regional at Broxtowe on Sunday, one bloke blew up his gearbox, changed everything for the next round, and blew it up again. Both times it was the o-ring that gave way and the pin destroyed the box. He sold his car there and then for £175!!!!!

This is a easy and quick fix. And its PERMANENT. you will never need to replace them.