The photo shows a homemade tool for holding the rear flange and a bearing puller with a homemade plate. The long pieces of all thread are needed to reach the middle transmission bearing. You might want to have a second pair which is shorter. Since some of the tools must be purchased and/or made, this is an excellent opportunity for some collaboration with other members of your local Triumph club. For example, two members of the Green Country Triumphs have the Churchill circlip tool. There is one pressure gauge and overdrive test stand within the club. These tools are available to all club members.
Note about removing and installing bearings
When pulling or installing the large ball bearings in the transmission and overdrive, keep the following in mind. The outer edges of the bearings are an interference fit in the aluminum housings and should move readily unless they are stuck. If they’re stuck they should free up by lightly tapping with a brass punch. In a worst case, you may need to apply a little heat to the housing with a propane torch. IF YOU HAVE TO USE A LOT OF FORCE, STOP, BECAUSE SOMETHING IS WRONG! One of our favorite mistakes is to try removing the input shaft before the counter shaft has been dropped to the bottom of the case. Your gears will break if you applying a lot of force when the gears are binding. The fit of the bearings on to the shafts is a press fit and should be removed with a bearing puller or press. Use common sense, not a bigger hammer.
The ball bearings are not designed to carry a side load. When you press a bearing on a shaft, press on the hub of the bearing not on the outer edge. If you drive it on, use a piece of pipe with an ID which is a bit larger than the shaft (standard 1 ¼ inch pipe for most bearings).
The following references have been used during the preparation of these articles.
Triumph TR2 and TR3 Service Instruction Manual, from Standard-Triumph
Haynes Owners Workshop Manual for the TR 2,3,4 and 4A.
Autopress Workshop Manual for the Triumph TR5, TR250 and TR6
Service Instruction Manual for the Laycock de Normanville Overdrive, from Standard-
We’ve also looked at later versions of manuals 1 and 2, i.e. official workshop manual for the TR250 and TR6 (Bentley manual) and the Haynes manual for the TR250 and TR6. They have similar information to the earlier manuals; however, there are variations in some of the specifications and tolerances.
We would like to thank the following people for assisting in this effort.
Nelson Reidel for his wonderful set of articles. If they were still available, there would have been no reason to write these.
Dave at Crossroads Auto for helping us through our first rebuilds. Crossroads is now close and we understand Dave is somewhere in Florida.
Everyone that has given tips on the net and in the various discussion groups
Mark Bradakis facilitator of the discussion groups