| One small problem we encountered was how to | | | | space we prepare for the long haul of heaving the |
| get the four coupling bolts back into their | | | | box (heavy when you are kneeling in a cramped |
| respective holes once in position. They had | | | | position and leaning forward) onto the engine bolts |
| wriggled out after some difficulty when removing | | | | and then getting all the nuts and washers on and |
| the gearbox and we worked on the premise that | | | | tightened correctly. My suggestion of going on |
| what came out must go back in. However, on | | | | through into the engine, removing the bearings |
| re-assembly the angle was so acute, there was | | | | and checking them was met with astonished |
| no way they would line up sufficiently to access | | | | incredulity! - they had been replaced previously |
| the holes in the gearbox coupling flange from the | | | | and were fine, so my brand of humour was |
| forward engine side. | | | | treated with the contempt it deserved! |
| Well, as predicted, the best laid plans very often | | | | The only alternative (after much debate) was to |
| get interrupted - and so it is with our schedule for | | | | bolt them up from the aft side with a spacer |
| having the gearbox back into Patricks' yacht by | | | | under the bolt head. This was tried on one, but as |
| this Saturday. Our gearbox expert Barry has | | | | the lock nuts are half as thick again as the bolt |
| completed the reconditioning and we have it back | | | | head, we felt the clearance from the gearbox |
| with us now. However, due to unforeseen | | | | casing was insufficient - it was down to 1.5mm. In |
| circumstances we are unable to fit it this | | | | all probability this clearance was enough, but it |
| weekend and have put it back to Wednesday this | | | | looked way to fine for our liking and in its original |
| coming week. | | | | position the clearance was around 3mm. What to |
| Barry, of 'Marine Gearbox Services' is one of the | | | | do? |
| very few and fast disappearing doyens of marine | | | | In the end it was quite simple - we obtained |
| gear box maintenance, repair and reconditioning. | | | | some shiny new locknuts which Patrick ground |
| With many years of experience under his belt | | | | down on his workshop grinder, taking off 1.5mm |
| there is no marine gearbox that he doesn't know | | | | from the underside. |
| inside out (excuse the pun) and never comes up | | | | Another dinghy trip out to the yacht saw us |
| short. His knowledge on all things gearbox is | | | | crunching down around the engine again and fitting |
| profound and being very particular in his approach | | | | the new nuts. Voila! they fitted perfectly, and with |
| you will always be assured of the best, and have | | | | the additional spacer under the bolt head we now |
| complete confidence in his work. | | | | had 3mm. clearance between the nuts outer |
| He showed and explained to us exactly what was | | | | surface (the bolt end being flush with the lock nut) |
| causing the problem of the boat slipping out of | | | | and the gearbox casing - looked much better, and |
| and back into gear from time to time and what | | | | along with peace of mind, it gave us confidence in |
| parts were worn and needed replacing. It is not | | | | a job well done. |
| the purpose of this article to supply a fully detailed | | | | All that remained now was to couple to the 'drive |
| manual of the work that needed to be done, | | | | saver' and the shaft coupling and this was a |
| suffice to say that friction clutch plates (sintered | | | | breeze. The gear cable strut was then bolted |
| bronze) and steels were worn, the selector fork | | | | back into position and the gear cable attached |
| was too slack as was the selector ring. All these | | | | ensuring it was placed in its correct groove. |
| parts to be replaced along with the bearings, and | | | | The moment of truth had arrived when it was |
| all seals and gaskets. Any other parts Barry | | | | time to start the engine and test that the gears |
| considered needed to be replaced as he worked | | | | would take up and operate correctly. With the |
| through the job would be. | | | | engine on and running Patrick slipped it into the |
| Believe it or not, the Hurth gearbox does actually | | | | forward position - after a moments hesitation |
| contain all those parts. It is difficult to believe that | | | | there was a satisfactory clunk and she was in |
| (a) that many bits are required for a simple | | | | gear - into neutral and into reverse - same clunk |
| forward and reverse gearbox and (b) they all fit | | | | again and she was in reverse. Grins all round. |
| into that limited space. It was a wise decision on | | | | Everything was working as it should so the kettle |
| our part to take it to the expert and not attempt | | | | was put on and a sweeter cup of tea was never |
| to dismantle it ourselves. We had a very | | | | enjoyed more. |
| informative time with Barry and on coming away | | | | Patrick has just returned from a few days sail up |
| we wondered what will happen when all the | | | | the NSW coast and reports that when motoring |
| Barrys' of this world stop their work - a rare | | | | the gears are working perfectly. |
| breed indeed. In the meantime however, Barry is | | | | Lessons: With a little time and patience no job |
| fully occupied with this work and not planning on | | | | cannot be tackled on your own boat. |
| giving it up any time soon. | | | | Never be afraid to consult with the experts - in |
| Having admired the re-conditioned gearbox with | | | | this case it was Barry of Marine Gearbox |
| its brand new coat of paint from all angles and | | | | Services. |
| following several false starts (colds, 'flu and strong | | | | When uncoupling the gearbox make sure you |
| winds, big chop in a dinghy) Patrick and I find | | | | leave the four coupling flange bolts in position in |
| ourselves back on board and fully prepared to | | | | the flange - this will overcome any problems |
| re-install the gearbox. | | | | when re-fitting. |
| Hunkering down into position in the cramped | | | | |