Hi All, almost finished my Fairey OD rebuild thread so I thought I would share my progress.
I bought a later model split case Fairey early last year for my HJ47 that ended up having a busted shift fork, which was unfortunate as I was hoping to just put it all in without any extra work. Good thing I checked as the synchros were absolutely shagged too. And I can put in the longer shaft for the transmission style handbrake.
It seems that these are the two major problems with these units (fork, synchros), apart from that they should technically be stronger than a H55, more teeth surface area and bigger bearings...and hopefully more fun!
The shift fork is a piece of sh**, a single piece of cast bronze that is too slim for the job and with tight radius curves that create stresses where they all seem to break. The wear pattern also indicated that the fork didn't actually grab the hub properly but sat too far away and only grabbed it on one side of the equator which could lead to binding and breakage as someone pushes hard on the shifter to rectify it's stickiness. The piece that came off got crunched up too.
I decided it would be best to replace it, I did some careful measuring and some simple drawings on CAD which I can share if someone wants. The main piece was roughed out using a band saw from a piece of aluminium plate and some bronze pads were machined for the sliding surfaces, these are screwed on. The aluminium was machined parallel/perp relative the bolt hole side and the pad mounts. Some guys at work were kind enough to do this for me.
In place,
As I said before the synchros were badly worn, I thought that this could of been the end if I couldn't get some new ones. I knew that a company like Fairey would of just used some other off the shelf parts of the time. With a bit of luck and a google image search I found the synchros to be from an LT77 Land Rover/Triumph gearbox (part no: FRC8232). They were only 7 pounds each from the UK haha.
Above pic is from ebay, below is the old one
I have also replaced the bearings in my H42 and the output shaft bearing and idleshaft bearings in the transfer case and all seals, just waiting on some locktab washers and put on the overdrive counter gear plate and handbrake, hopefully it works after all this effort haha.
Mostly, finished product
I bought a later model split case Fairey early last year for my HJ47 that ended up having a busted shift fork, which was unfortunate as I was hoping to just put it all in without any extra work. Good thing I checked as the synchros were absolutely shagged too. And I can put in the longer shaft for the transmission style handbrake.
It seems that these are the two major problems with these units (fork, synchros), apart from that they should technically be stronger than a H55, more teeth surface area and bigger bearings...and hopefully more fun!
The shift fork is a piece of sh**, a single piece of cast bronze that is too slim for the job and with tight radius curves that create stresses where they all seem to break. The wear pattern also indicated that the fork didn't actually grab the hub properly but sat too far away and only grabbed it on one side of the equator which could lead to binding and breakage as someone pushes hard on the shifter to rectify it's stickiness. The piece that came off got crunched up too.
I decided it would be best to replace it, I did some careful measuring and some simple drawings on CAD which I can share if someone wants. The main piece was roughed out using a band saw from a piece of aluminium plate and some bronze pads were machined for the sliding surfaces, these are screwed on. The aluminium was machined parallel/perp relative the bolt hole side and the pad mounts. Some guys at work were kind enough to do this for me.
In place,
As I said before the synchros were badly worn, I thought that this could of been the end if I couldn't get some new ones. I knew that a company like Fairey would of just used some other off the shelf parts of the time. With a bit of luck and a google image search I found the synchros to be from an LT77 Land Rover/Triumph gearbox (part no: FRC8232). They were only 7 pounds each from the UK haha.
Above pic is from ebay, below is the old one
I have also replaced the bearings in my H42 and the output shaft bearing and idleshaft bearings in the transfer case and all seals, just waiting on some locktab washers and put on the overdrive counter gear plate and handbrake, hopefully it works after all this effort haha.
Mostly, finished product
