[Chrislong]

Hey Chris,
Try this...

Take gearbox out, and take apart completely.

1) Fit diff with bearings ONLY, put case together and screw it together with the two screws (no need for motor plate) - does it spin? if yes go to 2.

If no, the issue is the gearbox is putting side load on the bearings which binds them, you'll need to grind out the inside of the gearbox to widen it and release the pressure..... this was something we had with the very very first prototype cases and was resolved 100%.

2) If above spins, install the idler next with diff still in, and put case together. Does it spin? if yes go to 3.

if no, a) there is something wrong with those gears, try cleaning them, turning them around or new gears. b) if still no, the gear mesh is out, this I would actually consider extremely rare, if possible atall.

3) If above spins, remove all gears and install the layshaft only (with alloy sleeve) and assemble the gearbox. Does it spin? if yes go to 4.

If no, check it for movement side to side as it should have a slight amount of play, its likely to have side load on the bearings. I actually grind a little (very little) off that alloy sleeve even if it doesn't need it as putting the slipper on stops it floating.... grinding too much and the gear will clash with the case, so do it a little at a time.

4) if above was fine, fit the idler with the layshaft and put the case together. Does it spin? Im hoping you have found the cause already by this point, as it really should spin, but if no...

Clean the gears, turn them around then try new again. Im out of ideas at this point.

5) You know where I live mate, send me a text and your welcome to come over 9just bring the gearbox out of the car), I can give it a full on check over if all else fails.

Let me know either way tho.

Chris