[coily96]

Since fitting a 1L case to my sj80 ive noticed the jackshaft and input flange has a bit of play when turning the shaft back and forward by hand. When driving either selecting gears or loading up the driveline it makes a clunk when the shaft is under load. Ive
Had the tcase shifter boot off and can see the shaft/uni/flange spin when the clutch is let out apon taking off, when you press the clutch back in it spins the opposite way a fraction.

Is this because the case is gear driven or something internal is worn out?

[JrZook]

Most likely the thrust washers on the countershaft are worn.

[Gwagensteve]

Which direction is the play in?

Some clunking is normal with a gear drive case, but JR may well be right- it could well need a freshen up.

Steve.

[coily96]

Both ways but more clockwise

Noticed the noise is more noticeable as the rubber boot is off.

I also noticed when coasting along out of gear or clutch in it also has a rattle that changes with speed, going to change the fluid to be safe.

On another note what order does the selector stick, spring and bush go? I went to fit a new bush and there wasnt a bush inside to start with.

[Gwagensteve]

Ahh.. you mean the play is torsional - i.e when you twist the input shaft.

I wouldn't worry about that too much. It will have WAY more play than the original coil transfer, due to the difference in design between chain and gears.

The rattle could be due to a heap of things. Leaving the shifter boot off can make the shifter rattle, dust shields on the yokes can rattle, and worn unis can cause a rattle. I'd be surprised if changing the oil will make much difference.

Chain drive cases are much quieter, that's why suzuki swapped to the chain case in the coil Sierra. It's impossible to tell you if the play or noises are unusual over the interwebs, as you'd imagine.

If in doubt, by all means throw a rebuild kit through the case, It's not hard, but don't expect it to every match the smoothness of the coil case.

Bush goes in the case, followed by selector, then spring, then cover that twists into place to lock the stick in. If this isn't right you'll have a rattle from the lever for sure if the robber boot has been removed on the trans tunnel.

[coily96]

Thanks Steve great info

[coily96]

Is there a trick to fitting the cover that fits into place?

I managed to just fit the new bush in as it wouldnt go past the two slots that the cover locks onto, then put stick, spring and now cant lock the top peice into place. I knew i should have fitted the bush when the transfer was on the ground.