Before I drop this TT-02 chassis in the trash...

[JimD9999]

I can't assemble it because the spur gear is blocking the diff case from fitting in, it's like part C5 is too long.

The pin is fully seated in the gear.

I've examined it over and over and it looks 100% correct. 

[Twinfan]

Have you lined up the grooves in part GB3 and the spur gear with the MA7 metal dowel correctly, and have you pushed the GB2 bevel gear on nice and firmly?

[compass]

It's a bit hard to see on that photo, but i think you have switched the bevel gear with the bevel gear which should go in te diff. 

[JimD9999]

As I mentioned, the pin (dowel)  is correctly seated in the big gear,  down into the slot. The spur gear is pushed on as far as it will go.

The gears that go in the diff are much smaller and have a round hole, not the holes with flat sides that. fit onto C5 - it for sure fits on C5.

Well thanks for the input guys,

[Twinfan]

3 minutes ago, JimD9999 said:

As I mentioned, the pin (dowel)  is correctly seated in the big gear,  down into the slot.

Is it lined up correctly inside part GB3?

[compass]

can you make a photo off the other side of that bevel gear?

I still think that that is G2 from step 6 in the manual

 

[JimD9999]

2 minutes ago, compass said:

can you make a photo off the other side of that bevel gear?

 

[compass]

That is indeed the wrong gear. This is G2 from the diff

[JimD9999]

4 minutes ago, compass said:

can you make a photo off the other side of that bevel gear?

 

7 minutes ago, Twinfan said:

Is it lined up correctly inside part GB3?

Yes otherwise the big gear is not flush 

[Twinfan]

6 minutes ago, compass said:

That is indeed the wrong gear. This is G2 from the diff

Yep, looks like that's the issue!

@JimD9999 You need one of the two separate gears, not one of the four on the tree.  GB2 not G2.

[alvinlwh]

.

[JimD9999]

8 minutes ago, compass said:

That is indeed the wrong gear. This is G2 from the diff

G2 is the correct gear for there. It is the exact same gear that is in the diff.

[Twinfan]

4 minutes ago, JimD9999 said:

G2 is the correct gear for there. It is the exact same gear that is in the diff.

No it's not, they are different gears in the diff.  It says "GB2" in your pic, this is the gear you want for the part you're building.  You have the wrong gear at the moment.

[JimD9999]

8 minutes ago, alvinlwh said:

As everyone else had pointed out, the gear in your first picture looks too "flat". Compare the profile of G2 and GB2.

 

 

The all are 8mm tall.

[Pylon80]

10 minutes ago, compass said:

That is indeed the wrong gear. This is G2 from the diff

Yep, @compass hit the nail on the head. You could even tell from the back side of the gear that is was an internal diff gear instead of the proper bevel gear. The internal diff gear has flat spots too. They are intended to transmit torque to the diff outdrives. Both the diff outdrives and the prop shaft extensions are 5mm in diameter and both use flat spots. Time to open the diffs!

[alvinlwh]

.

[JimD9999]

10 minutes ago, Twinfan said:

It says "GB2" in your pic, this is the gear you want.  You have the wrong gear at the moment.

If the red x means "these gears" then that is what I am using. IF the red X means "not these gears" then I don't know what gear you mean.

[Twinfan]

This is hard work, I thought I'd made it as clear as I could!

Crosses are the gears you've used, and they are the wrong ones.  They're called G2.

I've circled the gears you need to use.  They're called GB2.

G2 is not equal to GB2.

 

[JimD9999]

7 minutes ago, alvinlwh said:

Agree! Open the diff, count the gears. There should be 2 x GB2 and 4 x G2. Easy way to figure out which is which.

DId that the big gear in the diff is the exact same one. FYI the small gears in the diff are G3.

 

[compass]

GB2 come loose in the gear bag. G2 gears come from the spreu in that bag. I don't think you have used them in the diff. It won't close because it is thicker. Did you build both diffs al ready? If not, then the two GB2 gears should be somewhere on your desk.

[compass]

make a photo of all the gears you have on your desk.

[Gebbly]

Sorry about the picture quality but heres a photo of the same parts on my mid-build TT02. The gear everyone is referring to is a very different shape.

 

[Twinfan]

2 minutes ago, compass said:

GB02 come loose in the gear bag. G2 gears come from the spreu in that bag. I don't think you have used them in the diff. It won't close because it is thicker. Did you build both diffs al ready? If not, then the two GB2 gears should be somewhere on your desk.

Exactly this  

[JimD9999]

9 minutes ago, Twinfan said:

This is hard work, I thought I'd made it as clear as I could!

Crosses are the gears you've used, and they are the wrong ones.  They're called G2.

I've circled the gears you need to use.  They're called GB2.

G2 is not equal to GB2.

 

I see well I can't find any other gears. Any idea where GB2 is? There were 4 G2's  on the two trees.

I guess I have some how misplaced GB2 I will look for it.

Thanks!

[Gebbly]

8 minutes ago, compass said:

GB2 come loose in the gear bag. G2 gears come from the spreu in that bag.

If you look at the instructions on page 22, the "G parts" section, you will see a picture of a sprue with 7 parts, including 2 of part "G2". To the right of that you will see a picture of part "GB2_x2".

Could you open the diff and tell us which parts you have placed inside there? If you have placed all the gears correctly inside the diffs then a single diff should contain

1 of G1

2 of G2

4 of G3

This would not leave any spare G2 parts for the drive shaft. It suggests you have also got something wrong inside the diffs.