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Countershaft Repairs


mattscuda

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Hey fellas,

 

New to the forum and banshee world. Been keen on these for a while and was able to get one the other day for next to nothing. Needs some work but I planned on a complete strip down and build.

 

So I have found that the previous owner had welded the sprocket to the countershaft due to it stripping. I've stripped the whole motor down anyways for a new set of rings and an easy gearbox fix. But now I've found this.

 

I have access to some workshop equipment (lathe, mill, welders, ect) and am competent with all the equipement.

 

I have a couple of ways of repairing the shaft but wondering if it will be sufice.

 

1) Weld the shaft and turn it down in the lathe and re thread the shaft (not sure if this will cause more harm than good)

2) Turn the shaft down and re thread with a smaller diametre thread

3) Machine a groove on the shaft and put a circlip in ( Sprocket will need to be tight so probably not a good idea)

4) Tap the shaft and put a bolt with washers to hold the sprocket on.

5) Buy a new shaft (would rather do a repair as it won't cost me anything)

 

What route would be the best option. I'm leaning towards the smaller diametre thread or welding and turning down.

 

Cheers

 

Matt

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1) i prolly wouldnt put localised heat (welding) into an output shaft on something i own, but if its yours...yeah fuck it, give it a go

 

2) that`ll work and shaft material is not weakend, will still use a decent sized nut, prolly my choice of all the "fixes"

 

3) NO...your sprockets will fuckout your splines over time,not a very long time either, sprocket is locked up for a reason 

 

4) yep that`ll work too, wont be able to put the sort of weight on it like the original set up, but for keeping a sprocket snug against the shaft, will suffice i guess (i wouldnt be happy with it initialy but then would prolly forget about it and not give a shit unless it failed)

 

5) THIS best option, even though most of these are viable^ they wont be as strong as per factory and a 2nd hand trans on here goes for about a $100

 

just my 2c

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Id buy a new shaft for a better peace of mind. By the time you chuck up on the shaft and machine it, you could possibly waste a couple hours taking your time. Id rather work a couple more hours of over time if possible to help pay for it. I work at a machine shop and could get it done for free but i still would buy a new shaft.

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Preheat it before you weld and have at it.

 

 

We stub Hardened! Tulsa80 winch shafts at work. They are so hard we have to heat them to a dull red to soften the metal so we can turn and prep it on the lathe. They never break where we welded them.

 

If you are comfortable doing it why not?

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new shaft p/n-29L-17421-00-00 82.46 this is for a 1999 there all the same I think

nut 6.11

washer 4.95

 

or ebay

 

used trany complete

 

59.95+12.35 shipping

84.99+15.00 shipping

84.99 free shipping

 

I would not fix a shaft that was messedup like everybody else said heat may weeken the shaft+the time to fix it just does not seem to be worth it when I can buy a used trany off ebay for around 80.00 right now

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Thanks for the replies.

 

Problem is I'm in Australia and getting parts or spares is a nightmare for anything here and they charge you an arm and a leg for it. Then if you get the part from another country you have to factor in more $$$ for the transport costs and the shipping time.

 

I've had a crack at it anyway and pretty happy with how it has gone. I might still order a replacement when i make an order for the other parts to rebuild the motor and have it as a backup in case it goes pear shaped. 

 

I've gone from the standard 18x1mm (i think) thread and machined it down to 16mm for a 16x1.5 thread. The problem with fine threads is that the depth is so shallow it is easier to strip. With the bigger pitch and deeper depth of the thread it won't strip out so easily and get just as much torque (80Nm) on the sprocket.

 

Turning the shaft down to the required size.

 

IMAG1060.jpg

 

Using a die nut with the tail stock to keep it square

 

IMAG1061.jpg

 

The new thread. I did later on put a slight radius on the end of the shaft to let the thread go all the way to the end.

 

IMAG1063.jpg

 

Using a 20mm bolt I machined it down to the shafts thread length as to get as much thread as possible.

 

IMAG1064.jpg

 

A slight recess in the nut to tighten on the sprocket washer

 

IMAG1065.jpg

 

Tapping the thread on the nut

 

IMAG1066.jpg

 

End product

 

IMAG1067.jpg

 

Just need to get the locking washer but I reckon it will last a long time.

 

IMAG1068.jpg

 

 

 

 

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