TOPIC:

It seems I'm looking for help with just about every move I make with this rebuild project. Anyway...I pulled the trans cover to replace the seals (leaky) and found some bad news. The output shaft collar has a big burr on the outside edge, and I found a broken O-ring behind the trans cover (right near the output bearing, on the output shaft).

Does this o-ring serve as a buffer between the collar and inner bearing race? What would cause it to break? What would cause such a bad burr on the output shaft collar? I'm really stumped and I dont want to put it back until I figure out what happened so it doesn't happen again. Any help would be greatly appreciated!! Thanks!!

I'll attach a diagram to refresh your memories. The collar and o-ring are number 20 and 21.

Post edited by: 79MKII, at: 2006/10/08 22:40

The o-ring is a seal for the oil in the trans area. The collar seals on the o-ring so oil will not come out. Were is the burr at on the collar? the end against the o-ring?

I think that the collar can come off without much disassembling... if it can, just pull it off, grind off the burr and stick a new oring in place. Then just flip-flop the collar and reassemble.

The old collar pulled right off, no problem. The
o-ring was still in place but was cut through completely. I'm afraid that if I remove the burr the collar will be shorter and may affect sprocket alignment or clearance to the trans cover?? I would guess that the collar, the sprocket, and the output bearing should all spin together if properly assembled. Is this right?

I guess this brings up another question: Is the collar designed to be a solid spacer between the sprocket and the output bearing? I guess when you tighten the sprocket nut you are seating it against the collar and then against the bearing? I don't see anything else that would stop the sprocket from pressing on the collar when the nut is tightened.

Looking at it more closely, I think the collar had the burr on the inside. I see now that there is a small recess between the bearing and shaft where the o-ring should fit. This would allow the collar to seat against the bearing and not harm the o-ring. The burr fits perfectly into the little recess, so something must have been spinning somehow?? I guess I'll check a price on the collar and maybe go with a new one.

Come to think of it, should the collar be flat on both ends? Maybe there is a chamfer on the o-ring end??

Post edited by: 79MKII, at: 2006/10/09 18:59

Anyone know how this collar functions exactly? I ordered a new one for $15. I'm just curious how the burr/broken o-ring happened so I can prevent it from happening again.

I am unaware of any chamfer and thought that the collar was more a spacer than anything else. I don't think it was designed to spin as it doesn't engage anything that I can think of to keep it spinning with the countershaft but I could be wrong. Never really thought about it but I can tell you I have assembled a bunch of them and never paid any attention to which end went on first. Doesn't mean I was right but I "DON'T THINK" it makes a difference.

Thanks George. I don't think that one end should be different either, but I will be able to confirm that when the new collar arrives. Regarding the spinning, it seems that the collar would be tightened between the back of the sprocket and the bearing race, so it may spin with the shaft and sprocket...maybe?? Either way, I don't see how it could spin and not the shaft or bearing. I'm not sure how that burr was created, but it's really bad.

Do you remember if the collar seats against the bearing or the o-ring? Now I'm really testing your memory

It seats agaist the bearing inner race. Just flip it and you'll be fine