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Albion Gearbox.

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Albion Gearbox.
Started at 09:31pm on the 4th November, 2018 by dave p
dave p Subject: Albion Gearbox.
i little while back I asked for advice regarding my gearbox jumping out of first gear. I've finally got around to stripping the box and the only thing I can find is what appears to be excessive wear of the notches into which the detent plunger locates. This is the only component which requires engine removal to get it out.(Deep Joy!) However, the amount of end float on this component, about 3/16,"is such that the detent plunger can engage in the notches fully at one extreme of end float or only about half the width of the notches at the other extreme.Is this normal? On other gearboxes I've worked on this would require shimming so that the two components lined up properly. Has anyone else seen this condition and would there be any negative results from shimming? Thanks in anticipation, Dave.
Posted: 09:31pm 4th November, 2018
stinkwheel Subject: Albion Gearbox.
You ought to be able to remove everything from inside the gearbox with it in-situ. The selector segment included. I know because I have. On mine, it gave a whole new meaning to "rough and ready". I fettled the notches and the profile on the detent a bit to make it engage more positively. However my main problem was damage to the dogs on the gear clusters.

You can remove the gearbox without removing the rest of the engine too. CLutch will need to come off. You'd also need to make up/buy a couple of 3/8" cycle thread half nuts then you can lock them onto the four studs that hold the box onto the engine and wind them out (may also need to move the mudguard aside). Undo the two triangular frame brackets and it should lift out sideways. You shouldn't need to mind, but it might save your back.

This was the damage to my gear clusters.





I just remembered. The pivot pin for the gear selector is held in by a large slotted grub screw on the rear of the gearbox. Remove this and the pin should come out backwards allowing you to remove the selector. You can see it clearly on the following photo just below the top right stud hole.

Posted: 10:47pm 4th November, 2018
Mark M Subject: Albion Gearbox.
I have had to replace a pin that was very badly worn at one end allowing too much movement of the swinging fork (is that what it's called?) which completely bu**ered up gear selection on a Redditch box, so yes, I'd say it is almost certainly the problem, or part of it. You'll have to remove the pin to shim it anyway so just replace it?

REgards, Mark
Posted: 11:13pm 4th November, 2018
Norm Subject: Albion Gearbox.
As we drive on the left out here the frightening bit was always from taking off from the lights and turning left, lean over and it would drop out of first. Took me a while to work it out but it was caused by the drive side bearing being loose in the housing and moving sideways causing it to drop out of gear. Not an uncommon problem
Posted: 01:13am 5th November, 2018
Norm Subject: Albion Gearbox.
Sorry goofed up it should be turning right
Posted: 01:14am 5th November, 2018
scotty Subject: Albion Gearbox.
No need for half nuts gearbox can slide back to allow stud to be grasper with thin slipjoint pliers on the unthreaded bit, then double nut with the secureing nuts.remember the studs are different lengths 2 long 2 short.on the s/h bike we bought previous clown had put the heavy duty washers that go under the nuts between the box and the engine, prim chain slipper was backed right off chain was drum tight. When you can go on this site and parts book section shows where things go. Doh.
Posted: 04:10am 5th November, 2018
Norm Subject: Albion Gearbox.
This is a dropping out of gear problem, not a selection problem. What happens when the drive side bearing comes loose in the housing the mainshaft sleve can move in and out about 10mm and this knocks it out of gear
Posted: 09:31pm 5th November, 2018
dave p Subject: Albion Gearbox.
Thank's for your replies chaps. I've had a go at it today with mixed results! The locking half nuts didn't work although it usually does in other applications. I decided to sacrifice the studs and undid three of them with a very good pair of grips.They came undone with a crack. The fourth one, lower offside, I couldn't get at. I'll try again tomorrow.I can't slide the box back because the top rear stud that passes through the triangular plates atop the box is sheared leaving the nut and a length of stud still in the hole in the casting and it cannot be withdrawn from the right-hand side. This must have been done at the factory because I've never laid a spanner on it from new. The four main studs have heavy steel washers under the 3/8" nuts. Well, three of them had, the fourth had a red fibre washer! The large bolt beneath the gearbox with the nut removed cannot be withdrawn from the left-hand side because it has a flanged head which hits the frame when I try to remove it. Oh joy!! I'll report back when I've applied the Dremel and a few curses.
Posted: 10:05pm 5th November, 2018
stinkwheel Subject: Albion Gearbox.
Yes, I had a dropping out of gear problem too. It's what happened when a badly made selector lead to improper changing and damage to the undercutting on the gear clusters (over the course of 30-40K miles). As a result, it would jump out of first. Something that got progressively worse until I had to ride off holding the lever up with my foot.
Posted: 10:28pm 5th November, 2018
dave p Subject: Albion Gearbox.
Yes, I've been holding the box in first with my boot until second can be used. I'm still interested in the enormous amount of end float on the gear selector thingy. This is the first m'cycle gearbox I've seen without either a cam plate or a selector drum.Is this amount of end float normal? Around 3/16"to 1/4".
Posted: 10:44pm 5th November, 2018
dave p Subject: Albion Gearbox.
NORM.Thanks for your comments but this problem occurs immediately I set off with a stone cold gearbox and without leaning the bike.The bearing seems to be firmly held in its' housing.
Posted: 10:55pm 5th November, 2018
dave p Subject: Albion Gearbox.
MARK I'll inspect the pin when I finally get it out and see what condition it's in.
Posted: 10:59pm 5th November, 2018
Norm Subject: Albion Gearbox.
Dave, these things are very primitive in there and I can't say I have ever taken any notice as to how much sideplay the selector has, but if you say it is going off at an angle then something is not square, something must be bent, should be easy to see as you move the selector. If it was me and the sideplay was the issue, I would make up a half washer and slip it between the case and the shifter and then put a spot of weld on it to hold the washer in place. What have you got to loose, the box is stripped down so easy to clean out after welding and at the end of the day it is only an Albion
Posted: 06:04am 6th November, 2018
Norm Subject: Albion Gearbox.
Dave, welding that is probably not my best idea, just push selector the way you want it to go and put a cable tie in there, you are only trying to prove this is the problem but I doubt that it is. If it solves the problem you can then think about pulling the motor out. Otherwise just replace first gear and the sliding gear, something must be worn in there
Posted: 08:47am 6th November, 2018
Norm Subject: Albion Gearbox.
Dave, probably not my best idea, just push the selector to the side you want it to be and put a cable tie around the shaft to hold it in place. You only want to prove that it is a problem with the selector. If it solves the problem then you can pull the box and fix the problem. I doubt this is the problem but if you are sure the bearing and mainshaft sleve are not moving then replace the first gear and the sliding gear but I would expect to see some damage on the dogs
Posted: 09:18am 6th November, 2018
dave p Subject: Albion Gearbox.
Well, I've finally got it all apart. I'm surprised it didn't jump out of all gears.The selector looks as if it was made by a myopic spotty herbert in a third form metalwork class. The profile of the detents and that of the detent plunger bare little relation to one another and only about half the width of the selector has been engaging with the plunger! I'm not yet sure how to proceed,I think the girls at the local sixth form college could make me a better component. The bike has been great over the last twenty odd thousand miles but I'm appalled, appalled I tell you, at this recent discovery. There isn't much material around the first gear detent so if I have at it with a file there's a danger that the thing will break. I think I'll have a ride over to our hosts tomorrow to see if they have a better component in stock as I'm sure they probably vary. A good excuse to have a ride on the Guzzi !!
Posted: 05:48pm 6th November, 2018
dave p Subject: Albion Gearbox.
Well, I've finally got it all apart. I'm surprised it didn't jump out of all gears.The selector looks as if it was made by a myopic spotty herbert in a third form metalwork class. The profile of the detents and that of the detent plunger bare little relation to one another and only about half the width of the selector has been engaging with the plunger! I'm not yet sure how to proceed,I think the girls at the local sixth form college could make me a better component. The bike has been great over the last twenty odd thousand miles but I'm appalled, appalled I tell you, at this recent discovery. There isn't much material around the first gear detent so if I have at it with a file there's a danger that the thing will break. I think I'll have a ride over to our hosts tomorrow to see if they have a better component in stock as I'm sure they probably vary. A good excuse to have a ride on the Guzzi !!
Posted: 05:49pm 6th November, 2018
dave p Subject: Albion Gearbox.
Well, I've finally got it all apart. I'm surprised it didn't jump out of all gears.The selector looks as if it was made by a myopic spotty herbert in a third form metalwork class. The profile of the detents and that of the detent plunger bare little relation to one another and only about half the width of the selector has been engaging with the plunger! I'm not yet sure how to proceed,I think the girls at the local sixth form college could make me a better component. The bike has been great over the last twenty odd thousand miles but I'm appalled, appalled I tell you, at this recent discovery. There isn't much material around the first gear detent so if I have at it with a file there's a danger that the thing will break. I think I'll have a ride over to our hosts tomorrow to see if they have a better component in stock as I'm sure they probably vary. A good excuse to have a ride on the Guzzi !!
Posted: 05:49pm 6th November, 2018
dave p Subject: Albion Gearbox.
In triplicate! How did that happen???????????
Posted: 09:29pm 6th November, 2018

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