Was on the downhill run of putting these hub gears in - both back and the front left done and just needed to reassemble the front drivers hub.
Well something is wrong - when I went to bolt the two halves of the front right hub casing together they would the two halves would not mate up - sits proud by a few mm and the main hub is locked - intially thought it was I had too many spacers on the wheel bearing so took off the square plate at the back so releasing any pressure on the wheel bearing but everything still remained locked up.
Something is very wrong. Either the new large hub gear is too thick, the hub casing is different somehow or I have the wrong spacer washers on the shaft.
Pulling the hub apart it is obvious the height of the outer rim (the teeth end) of the large hub gear is too large and is rubbing (being locked) by the hub casing when tightened up - the spacers are different diameters and can only go one way and this is correct.
The inner hub casing - you can just see the scrap marks at the pink pointer
Looking side on at the other casing with the gear - sitting proud
While the new main gears are thicker than the old gears the crucial faces on the inside are the same as the old gears so it is just the upper face that scrapes.
Here are the two gears side by side - old on the left - new on the right.
Interestingly the smaller new hub gear is the same size as the old one and does not fully contact right across the teeth of the new large hub gear.
The contact width is about 3mm less on the smaller gear than the larger gear.
What has caused my problem - either this last large gear is different to the others - no I didn't check them before and as the other three are in hubs I am not going to pull one out to check. The other consideration is that the hub is different to the other and is from another version - did Haflinger change hubs during production life?
What do I do about it - simply turn down the outside outer lip of the hub by 3mm - this area does not mesh with the smaller gear anyway and the inner faces are correct so they do not need touching.
Garry