You need to shim one of the idler gears over to one side. Have a look at the case - one of the layshaft bearings will slightly raised (non slipper side), and will rub on the idler causing it to fail. There's load room to do this and it will solve the problem.
Clean all the gears - I use clutch cleaner And use a scalpel and make sure every last bit of debris is out of the teeth of the the diff and layshaft.
Last edited by mattybucks; 20-12-2015 at 09:40 AM.
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