Propshaft

The original propshaft from the BW35 auto was modified by changing the output sleeve yoke to a type 9 version.

It was considered at the same time to lengthen the propshaft by 1" - but the company I used ( autoprop-uk ) had recently had some items lost in a fire and couldn't do the balancing. So we just changed then ends and spiders.

I decided to wait a while to determine if all was well before going to adjust the propshaft length.



It later occurred to me that a spacer on the axle would be a solution. I wasn't sure if it would be "safe" until I noted a few "propshaft spacers" for land rovers and Atlas axles available on eBay.

So here is the drawing for the Sunbeam.

Lofty volunteered to make it.







A week later and here it is - and it fits! (amazed my measurements were accurate but lofty made compensations for my lack of tolerances )
Perfect fit on the propshaft, slight interference fit on the Diff flange as I made the measurements the same for both sides. M8x50 class 8.8 were used as the 5/16" x 1-3/4" UNF grade S were just a little too short to fully fit the nylocs.
A test run proved it hasn't added any balance issues and I'm happier the propshaft fits further onto the gearbox.

type 9 gearstick adjustment and steering end stop

If you get the shortening of the housing slightly wrong then gear selection isn't easy!

not easy to see in the photo - but I had to push slightly down on the gear lever to select first and second - which leaves you open to the possibility of reverse at the wrong time.

The selector shaft gearstick connector needed to be rotated a small amount clockwise and be re-secured to fix the issue.


The steering arm on the drivers side would make contact with the oil cooler/filter housing.

After a while it was realised that the series 3 has an adjustable steering end-stop on the lower wish bone.
A tweak with the 9/16" socket and the steering was slightly restricted stopping the steering arm from making contact with the oil cooler.

type 9 gearbox "shortening"

The engine and gearbox was removed again in preparation for the engine mounts being welded in place. I forgot to remove the gearlever..!

A few measurement were taken, The main measurement for the shortening is 11" from front of tail housing to the front of gear lever casting.

With the gearbox removed from the engine the tail housing was removed.
Beware the layshaft can stick to the housing and pull out with it.. potentially leaving all the cogs and gears rattling around the bottom of the case.. I think I saved it in time.

Now the tail housing is in the ultrasonic cleaner. ready for the hacksaw..!