Propshaft fitting

peterux · #1 29th April 2006, 20:31

Evening fellow builders,

I got my propshat from Marlin this week, so thought I would pop it on this afternoon. Not as easy as i thought.
First the hole in the gearbox end flange was just slightly too small for my gearbox output spindle. After trying to force it on (yes, i know i shouln't have) it turned out there was a thin metal sleeve in the hole which popped out the back. It appears it is a pressfit in the hole. Tried fitting the sleeve first but then I couldn't get the flange to go over the sleeve. I have now lightly chamfored the sleeeve and will try again tommorow.

Second problem was that the gearbox flange Marlin have used is too large diameter and the flange rubs on the gear change mechanism where it exists the top of the gearbox. I don't have a lathe, so i have ground off 5mm from the edge of the flange. Has anyone else had this problem?

So not a very productive day?

Patrick · #2 29th April 2006, 21:27

Ours went on ok, but the end is rather oversize. It doesnt get in the way of my gear change so I have left it alone. I ordered it so I could fit the rubber doughnut from the donor but the adjustment goes the wrong way. Im going to try without to start with and see what its like and if needed get it modified else where.

The other end that attached to the diff was a lot stiffer, I've not taken it off since bolting up the first time. I suspect it will be a right bugger to get off again!

peterux · #3 30th April 2006, 09:06

Hi Patrick,
that's funny, I had absolutely no problem with the diff end!
Even if your propshaft was short enough, you can't fix the rubber doughnut with the flat flange that Marlin have specified. The bolt heads fixing the gearbox flange to the doughnut will foul the flat flange on the end of the Marlin propshaft. They have obviosly never fitted a doughnut with this design.

BTW, i'd check the clearance of the top of this flange with the gear change bush as mine was very close. It's the first bush that connects to the gearchange lever where it exists the gearbox and quite difficult to see.

I wish I got my original prop shaft shortened now, which was one option I considered.

Peter