Well the side plate is repaired. Now the issue is getting the Jack plate to engage the spool properly. Reel goes into free spool fine. When Jack plate lever is pushed forward, the reel usually engages as the handle is turned. However, about every 8th time of disengaging / engaging, it fails to engage correctly. As I turn the handle, I only feel the friction from the drag, but the spool does not engage. I have to move the handle back and forth, and sometimes manually move the spool, to get it engaged. My guess is the spool is not quite laterally aligned correctly, and maybe the pinion gear, or something, is binding. I say this because I can't seem to get the spool lateral movement adjusted properly. There is either too much play, even with the side adjustment screw tightened down, or there is no play if I add a shim/spacer behind the bearing. I'm using the schematic for a 500 "S" because I can't find a schematic for a 500 "C". Do I just need to keep playing with shims behind the bearings? If so, are there any tips to help in finding the correct combination of shims. When the side plate is removed, the Jack plate seems to snap in and out of position as it should. Am I missing something else? Thanks in advance.
I don't know an easy way, start with no shims and go from there. Normally you don't need to shim the handle side on those but the new bearing cap might be a tiny bit different. A giant pain having to pull it apart every time
Thanks Swami. I don't mind pulling it apart and putting back together. Just needed to know I'm on the right track.
Check the bare spool and bare pinion gear to see first if the pinion drops down and engages the shoulders of the spool shaft.
Thanks Alan. Just checked, the bare pinion fits the spool shoulder with just some very slight rotational play. What you're saying is the problem certainly makes sense. When the side plate is off, pushing the Jack lever forward snaps the Jack plate so the pinion can engage the spool. When assembled, moving the jack lever forward, there is no snap or engagement until I forcefully rotate the handle, and sometimes the handle just spins with no engagement. If I make the drag pretty tight, it usually engages about every time. How do I fix this?
is this a 540-3.2 or 540-4.6/540-5.5?
to me, it sounds like the spool needs to move over left to right for a right-handed reel.
Thanks Bryan it's a C540-3.2. I was thinking the same thing, so I added a plastic shim/spacer? to the left side and it still won't engage correctly, and now it also clunks when in free spool. I'll keep trying...
There are only two positions on the spool that will engage the pinion. When the slot lines up and 180 degrees from that position. Usually you throw it into gear when the line is disappearing on the spool quickly, but that is one heck of a time to have it not go into gear! Cup your hand and slap the left side plate hard! Don't laugh, it sometimes works! Sometimes you have to slow the spool down for it to finally drop in. Polish the shaft and the pinion, oil it with you know tsi321 and don't forget the slap method. When this is accomplished, you will soon be known as a Newell head.
It turns out the right side plate, where the bearing fits, is missing, or wore down, the plastic ledge the bearing sits on. It was completely smooth inside and looked "normal" to me since working on Newells is new to me. Have it working pretty well now with several shims/spacers, and will look for a replacement plate for a permanent fix. I did buy a used "C" 500 plate, but the jack lever cut out is about 45 degrees off: it faces aft. Did I buy a left handed plate, or is there a way I can use this plate?
The jack lever is in a different location on the 3.2 model, the bridge is set up differently
Does that mean I can only use a 500 series 3.2 side plate? Working on Penn reels is so simple compared to this Newell haha. Oh well...learning as I go.
Yes only a 3.2 side plate. It's strange, no idea why it's like that. Makes no sense to me anyway. The other series most parts interchange
Ok thanks for all the help Swami.
so weird. what it sounds like is that you have a left handed set of gears in a right handed reel. :-\
Pictures would help us too. Okay. It'll help me out trying to think of a resolution.
To clarify, the reel is operable now with several spacers behind the right bearing to keep the bearing in place. Apparently the plastic ridge in the right side plate bearing cavity, that stops the bearing from moving farther outboard, is completely worn down. In the meantime, I'm on the hunt for a Newell 540-3.2 right side plate since this model has a different Jack plate and jack lever setup than other Newells. I appreciate all the help from everyone: really enjoy and learn a lot from this site!
Quote from: Bryan Young on January 25, 2023, 07:58:19 AMPictures would help us too. Okay. It'll help me out trying to think of a resolution.
yeah, i was thinking the same thing.
Pretty sure the only difference in the side plates is the slot for lever. No big trick to cut a slot. I've done that using blackie guts on other side plates so the lever fits. There will be an extra slot but it's not like those side plates are close to water tight. Kind of a hack but probably better than a stack of shims
I'll give it a try Swami. The side plate was relatively inexpensive. I was concerned about water getting in, but I'm sure I can come up with something.
Here's what I found. The first pic is the replacement side plate with the bearing "shelf" intact. The second pic is the original side plate with the shelf worn out.
7D2299A0-7F76-448B-B332-7121035F0389.jpeg
9639BBFA-70A4-4D18-B08E-0A39013FCCF9.jpeg
Not sure why pics loaded twice???
My final post (I hope) with this reel. Took Swami's advice and cut a slot for the jack handle in the C533-5.5 side plate using a Dremel. Also needed to enlarge 4 of the 5 holes in side plate for the screws to fit through and mount to frame. Not much plastic to work with as diameter of plastic posts were a bit smaller than the original side plate's. In the end, the reel is working very well, and my friend will again get to fish with a reel that has nostalgic meaning to him.
Appreciate all the advice and support.