2010.Gearbox 
Assembly #14. Mounting flange is attached to the clutch housing. Bolts and washers are new. Non-drying liquid packing (got it from Motonet) is applied to matching surfaces (apply the packing to only one surface).
Assembly #14. Mounting flange is attached to the clutch housing. Bolts and washers are new. Non-drying liquid packing (got it from Motonet) is applied to matching surfaces (apply the packing to only one surface).
Viewed: 364 times.

Assembly #15. Output shaft coupling and O-ring (not visible on the photo) are in place, nut is tightened and calked.
Assembly #15. Output shaft coupling and O-ring (not visible on the photo) are in place, nut is tightened and calked.
Viewed: 427 times.

Shifters, old and new - find the difference. ;-) Old shifter had depletion of about 2 mm.
Shifters, old and new - find the difference. ;-) Old shifter had depletion of about 2 mm.
Viewed: 412 times.

The gearbox put together. Note the red non-drying liquid packing between the mounting flange and the housing.
The gearbox put together. Note the red non-drying liquid packing between the mounting flange and the housing.
Viewed: 352 times.

The gearbox from the mounting flange side. Ready for installation.
The gearbox from the mounting flange side. Ready for installation. *
Viewed: 478 times.

The gearbox is installed, shafts are aligned, coupling bolts are tightened. I had to detach the engine from the mounting places and pull it few centimeters forward to remove and re-install the gearbox.

I refurbished the gearbox in spring 2010 and it worked well during whole 2010 season. I got smooth forward and reverse gear shifting, smooth torque control, much more output power, faster speed gain, better steering at low speeds and better braking.

The work took a while, but with acquired experience and good tools I perhaps would do another gearbox in 5-6 hours (not counting gearbox removal and installation) - that is what Leevene wanted 1000¤ for. Good hourly price they have...

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I asked myself if it was a good thing to refurbish the gearbox or would it be smarter to invest in a brand new engine. Time will give the answer - if the engine and gears work for another 5 years, then yes, it was a good thing to do. If the engine or gearbox fails completely after a year or two - I have made wrong decision. So, we'll see.

At least I got the experience and some nice photos to share... *
Viewed: 464 times.

Old, well worn out cone. Note the difference in width of front and read shifting surfaces.
Old, well worn out cone. Note the difference in width of front and read shifting surfaces.
Viewed: 419 times.

Worn out front shifting surface and well polished cone working surfaces.
Worn out front shifting surface and well polished cone working surfaces.
Viewed: 398 times.

Forward gear polished to mirror quality - you could see my house interior reflection in the gear surface. I have no idea how long it takes for the cone to do such job - a lifetime?..
Forward gear polished to mirror quality - you could see my house interior reflection in the gear surface. I have no idea how long it takes for the cone to do such job - a lifetime?.. *
Viewed: 435 times.

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