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Gearbox refresh - 3 synchro
https://ausmini.com/forums/viewtopic.php?f=2&t=97472		 Page 1 of 1
Author:  simonw [ Mon Jul 09, 2018 3:29 pm ]
Post subject:  Gearbox refresh - 3 synchro
Have a just split a spare box and am starting the learning curve on gearbox reconditioning , and while I am fully aware that I have a lot to learn and won't learn this on a single rebuild am willing to give it a crack !

This a box of unknown origin .. cleaned and stripped...including the synchro bearings going flying (yes i forgot) :lol:
My original box is coming back from the ship this week after being cleaned. Its the one I will be rebuilding .
I would love some insights on identifying gear condition and general condition of parts . Hopefully this will be a progressive and documented thread with all input welcome as I go.

Which rebuild kits have ones used?
Which bearings are must do's?

I have read a lot of the rebuild threads and general questions so sorry if I repeat a few of those questions as I go .

Anybody in Brisbane with special tools that I could borrow along the way will be much appreciated!

Thanks chaps!
Author:  winabbey [ Mon Jul 09, 2018 4:11 pm ]
Post subject:  Re: Gearbox refresh - 3 synchro
Have a read of these threads if you haven't already.

viewtopic.php?f=2&t=95454

viewtopic.php?f=2&t=77845

Also, I found this article from a 1972 issue of Cars & Car Conversions magazine to be a great help when I was a newbie mechanic.

Click twice to enlarge the image

Attachment:
CCC Sept 1972 Rebuilding Gearbox p62_63.jpg


Attachment:
CCC Sept 1972 Rebuilding Gearbox p64.jpg


Attachment:
CCC Sept 1972 Rebuilding Gearbox p65.jpg
Author:  simonw [ Mon Jul 09, 2018 5:16 pm ]
Post subject:  Gearbox refresh - 3 synchro
You are of excelling value on this forum winabbey thank you

ImageImageImageImage

Bit rusty this box so the bits were degreased and phosphoric acid treatment hence the blue look


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Author:  simon k [ Tue Jul 10, 2018 3:14 pm ]
Post subject:  Re: Gearbox refresh - 3 synchro
FYI that gearbox is from a Morris 1100S, it's also the casing (22A1288) that was used in the later MK1 Cooper S, but with different gears. The 22G231 code on the laygear you have there identifies it as 1100S (actually, just non-Cooper S) gears
Author:  simonw [ Wed Jul 11, 2018 6:36 pm ]
Post subject:  Re: Gearbox refresh - 3 synchro
Thanks SK great info.

Image

So this shaft is knackered

Image

How does one assess baulk rings?

Image

Is it customary to replace bronze bushes when refreshing a gearbox? What would be the tolerances?




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Author:  cgo [ Wed Jul 11, 2018 7:18 pm ]
Post subject:  Re: Gearbox refresh - 3 synchro
Simon,
Have sent you a photo of checking baulk rings.
Clive
Author:  drmini in aust [ Thu Jul 12, 2018 8:33 am ]
Post subject:  Re: Gearbox refresh - 3 synchro
Give the reverse idler bronxe bush about .001" clearance after press fitting.
Author:  TheMiniMan [ Thu Jul 12, 2018 10:46 am ]
Post subject:  Re: Gearbox refresh - 3 synchro
Just don`t forget (with all 3-speed syncro boxes) "mainly"--> 2x things

On the first/2nd hub-assy, there is a small "pawl" inside the hub,,, don`t forget to put it back in

& 2ndly,,, the outer-ring needs to "line-up" with the ramp to that Pawl

you will have to look closely when re-assembling the hub assy when you fit your new detent springs
there is a tint little "ramP' on one spline,,, that ramp needs to line-up (IE: the outer-ring needs to be oriented correctly) so the Pawl lines-up with that little ramp

otherwise 2nd gear selection will not-only be very difficult to engage but if/when it does it will crunch every time.
it`s a catch for young players :-)
the rest is per std issue mini gearbox over-haul,,, IE: make sure everything is absolutely spot-on,,, it`s a VERY MAJOR opperation fitting it all together,,, fitting & conecting the power-unit into the car,,, only to find you have stuffed-up some silly little thing inside the box & have to rip it all apart again to correct that :-)
cheers & have fun, & if you need a hand with advice along the way please don`t hessitate to cal me, happy to help if/where i can,
Matt 0407 135 656
Author:  simonw [ Fri Jul 27, 2018 5:44 pm ]
Post subject:  Re: Gearbox refresh - 3 synchro
Thanks for the great info Matt! Appreciate it .

Well got the box back from cleaning and decided to count he pinion teeth.......15. Interesting ? Means moke right ?haha what the hell is it doing in the deluxe! Potentially a very lo geared box then.

May have to source a 4 speed or might carry on faffing about with this one. Will be interesting to see what gears it has in it.
Author:  simonw [ Fri Jul 27, 2018 5:47 pm ]
Post subject:  Re: Gearbox refresh - 3 synchro
ImageImage
Image


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Author:  simonw [ Fri Sep 07, 2018 4:07 pm ]
Post subject:  Re: Gearbox refresh - 3 synchro
Just picked up a 4 synchro 22g846
I think it has a 3.6 diff so that will work nicely .
Actually might just rebuild this one and chuck it in .

Image


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Author:  drmini in aust [ Sun Sep 09, 2018 8:31 am ]
Post subject:  Re: Gearbox refresh - 3 synchro
Better idea, parts are more available than for the 3 speed. The 22G846 box is same as a 22G1128.
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