This is on a 2J head from a True-Trace (not actual photos). This mill has seen very little action as it came from a tool and die maker, not a production shop. EVERYTHING inside the housing is in first rate condition, but the two shafts (Cluster Gear Input Shaft and the Cluster Gear Shaft) appear to be too close preventing the gears from meshing when operating the 3-position speed selector. I can force them to mesh, but they are very, very tight. This problem exists whether the speed selector is installed or not.
I have removed and disassembled the two shafts completely. Every tooth on every gear shows very slight wear and the gears are in excellent condition otherwise (no nicks or banged edges), the bronze bushings are not worn (holes are round), bushings were oriented as originally installed by BP, nothing obvious with the casting (no cracks or hammer blows evident). The only thing worth noting is the Worm Drive Gear key has a very slight shearing indent, but fits comfortably in the key slots of the gear and shaft. All other keys and keyways are straight and true.
I chucked up the shafts (less than 2 tenths runout each) with gears to visually inspect while turning slowly to look for runout of the gearsets with nothing evident. Last night I thought I might remake the bronze bushings for the Cluster Gear Shaft with the bore slightly offset from center to provide some clearance between the shafts, but that would affect the relationship of the bevel gears to each other - not sure if I could adjust the bevel bears clearance afterwards.
I've been chasing this problem around for several hours. Did BP provide any sort of clearance adjustment for this assembly? Any ideas would be appreciated.
I have removed and disassembled the two shafts completely. Every tooth on every gear shows very slight wear and the gears are in excellent condition otherwise (no nicks or banged edges), the bronze bushings are not worn (holes are round), bushings were oriented as originally installed by BP, nothing obvious with the casting (no cracks or hammer blows evident). The only thing worth noting is the Worm Drive Gear key has a very slight shearing indent, but fits comfortably in the key slots of the gear and shaft. All other keys and keyways are straight and true.
I chucked up the shafts (less than 2 tenths runout each) with gears to visually inspect while turning slowly to look for runout of the gearsets with nothing evident. Last night I thought I might remake the bronze bushings for the Cluster Gear Shaft with the bore slightly offset from center to provide some clearance between the shafts, but that would affect the relationship of the bevel gears to each other - not sure if I could adjust the bevel bears clearance afterwards.
I've been chasing this problem around for several hours. Did BP provide any sort of clearance adjustment for this assembly? Any ideas would be appreciated.