As I understand it, there are two important pieces to this (again thanks RJ and let me know please if I got it wrong)
1. When you install the bushing, it has to be expanded in the gear hub so that it can expand no further.
2. Then, it has to be finished to the appropriate size (0.002 +0. -.0005) for the shaft
3. We discovered three things so far
a. When the bushing in the gear was correctly fitted at 1.5 thou over, and then the gear assembly completed (and strong snap ring installed) now all a sudden it starts to bind up. I would never have guessed that the snap ring would compress the hub at the end enough to take up half a thou-- but it did!
b. The finishing has to be absolutely perpendicular and straight-- no offset.
c. Once installed and all good, file down the bush to match the oil passages, and clean the snot out of it, using brake cleaner then detergent and water, followed by brake cleaner again. It took a good while to get all the black grinding residue out of the bushing.
Alphil unless you have a super supply of reamers, I doubt you will find one that is exactly correct for your shaft diameter + .002. I think the best that can be done is get close, then hone it carefully and slowly. I would not use an adjustable one, I doubt you can hold tolerance with it
Richard, did I miss anything critical or other important details? Many thanks
74 GTV with 10548's and Ingram pump
71 Spider 1750 BOMBER ; 1995 LS 78K tight fast car
Last edited by goats; 10-08-2014 at 12:46 PM.