[Chuuchuu]

Originally Posted by CDN_Stalker

Whenever you install new bushings and/or gears, you should check the shimming to make sure it's good. Not all bushings are made equal, some can easily use the stock shim types and locations, others might need one shim less or one shim more to make it work right. I'd say that the bushings you installed are not quite the same as the stock bushings, therefore too tight of a shim job, causing the problems you have.

Reinstall the metal bushings, take out the cylinder and tappet plate, then put your mechbox together and snug down two screws (middle and back works best), then use a small screwdriver to spin the gears. If they don't move much at all or takes a lot of effort, you found your problem and are on your way to the first (of many) shimming experience of your life. Good luck!

BTW, it's easy and straight forward, just time consuming. Ideally you want to check each gear's shimming individually, start with only the spur gear, make sure it spins and doesn't have any side to side movement. Then the sector gear alone, then the bevel gear alone. Then all three, and you are done. They should spin maybe a 1/4 to a 1/2 turn after you give them a shove.

Actually I didn't even try doing that yet, and closing the mechbox while spinning the shims sounds a lot more feasible than what mechbox.com suggests. I shall try out your advice, many thanks