What's the most feared noise during gearbox assembly?
"PING........."

I posted this in reply in gallery forum, but it's worth putting here.
One of the most worthwhile tools I've made, IMO.

ASSEMBLY TOOL FOR BALLS INTO SYNCHRO HUBS
I have not lost a synchro ball on assembly since making this tool up.

TO MAKE:
1. Get an old 1st gear, either a 3 synchro one will do. (all the splines are same inside anyhow).
2. Look inside where the balls ran, there are 3 shiny marks, between the cutouts for the baulk ring.
3. hold gear in a vice with the cutouts facing downwards.
4. Take a 4" angle grinder with a well worn cutting or grinding disc on it.
5. Grind a 45* (approx) angle about 6mm wide, into each gear tooth where the marks are. ie equal spaced.... 3 required.

TO ASSEMBLE:
1. Put this tool on the bench with the 3 grooves facing up.
2. Fit your synchro hub (either one you are assembling) inside it from top. Fit the 3 springs. Sit the 3 balls in the grooves.
3. Push the hub into the tool. the balls will run down the grooves and into the hub.
4. Put the outer part of your synchro hub on the bench. Put the tool and hub assy on top. align the synchro cutouts of ring with those on the hub and then push the hub down thru the `tool' into your synchro outer ring.

See pics..... sorry they are a bit dark...

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

Here ya go Doc, added a little light on the subject for you

Thanks for that...

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

Thanks for that Dr Mini. Have not rebuilt a mini box yet so I havent experienced the 'ping' but Im sure it will come in handy. Now to find a spare first gear........

I've got my gerbox apart again and I had to put new springs into the hub.It took 3 people 10 minutes to get the thing in again.The balls kept going everywhere.

BTW what is the purpose of the springs and balls. I've been told part of my problem in crunching from 3rd to 2nd was weak springs.

Positive detent , locates the gear and stops it from dis-engaging by itself, that is popping out when backing off the throttle. Crunching when engaging gears would be synchro rings.

_________________
Over 1,000,000Km, but now my retirement restoration project

Synchros looked within specs but I have changed them anyway.The primary gear end float was also out, now fixed.

No, sorry, that function is the selector balls & springs...

It's more involved..
Reason for the 3 inside the synchro assy is to apply an axial load to the baulk ring when you engage that gear. Gear cone friction then drags the baulk ring around, until the outer synchro sleeve can apply direct load to the ring via the 3 lugs. When gear speed is equalised the synchro cone will centre and allow the gear to be engaged.

If these springs are weak you will crunch gears, even with new baulk rings.... Check 'em while they are out.

Trivia... early 850 `cone synchro' boxes had 6 springs in each synchro ... and the synchros were friggin' useless.

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

So the advise I got could be right.Soon find out I guess.I hope to have the box back in in the next couple of weeks,just waiting on my new 1st/2nd selector fork to arrive.

Use the longest springs you have. Any that are short, chuck 'em.

If you buy the current MiniWorld mag, there's some pics of how to check their strength with a bench drill and bathroom scales..

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

haa haa hee hee,,,Ahh,,,,the young Doc is still learning

But!!!!!!!!!!,,,,If you`d like a way better tool for the job Kev,,,do yourself a favour & grind those 3 slots a little different,,,,one of them only about a ball width deep,,,,the second one about 2 balls width deep & then the third one about 3 balls width deep

hee hee,,,that way you can easy fit in one ball&spring at a time then move the outer ring a tad & fit the second,,,then move the outer ring a tad more & fit the third

it`s way ways better,,,we`ve done it this way since 1965

If you can get the drift of what i typed here then cool,,,if not then i can take a pic of my tool (mmm maybe my tool isn`t the right word here )

anyways, let me know if you`re confused & i`ll stick a pic up

_________________
No offence intended here but--> anyone writing a book about minis 30 years ago may not have experienced such worn or stuffed-with components as we are finding these days.

You should put your heart & soul into everything you do.

I know what you mean Matt, but mine works.. & I haven't `lost a ball' since I made it! (1995 I think).

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I bought six new ones and they are longer.Last time I was able to actually put the springs and balls in by myself, this time not a chance so I'd say there is a bit more strength in them. For a few dollars each its not worth not changing them.

These tidbits are so cool, I wish I broke gearboxes more than once every ten years so I could play with one of these tools.

I feel like pulling apart my engine just for some excitement now.

I feel so disapointed with myself

_________________
SooperDooperMiniCooperExpertEngineering

All garage work involves equal measures of enthusiasm, ingenuity and a fair degree of irresponsibility.

Great after the fact - I had the tool ready to go(thanks kev) but thought I would be right now the box was nearly together. Had all the bits in place but not the clutch end. Anyways checking(more like fiddling!!)to see if everthing worked well, pushed the 3/4 synchro hub a little too far...WHACK!! WHACK!!, both cheeks this time...those little ball bearings really hurt when they fly out - and I am thinking the springs are ok as they were following soon after at a great rate of knots!!

If it is in place and all is well....LEAVE IT ALONE ROBERT!!

I just never learn!!

Hooroo

Rob Forsyth
Miniot!!

_________________
Rob Forsyth
Miniot!!