6 replies to this topic

[rich2]

Hi,

 

I have rebuilt my pre-A plus gearbox for my 79 clubman. Everything cleaned, new baulk rings, new centre oil pickup. I now have 2 issues:

 

1. When trying to select first gear (by manipulating the selector rod with a screwdriver stuck through it) the synchro hub does not seem to want to fully click over to engage the first gear. It gets to about half way. I can push it over manually with my finger at this point but thats obviously not going to work when the engine is on top of it. Could this just be because there is no oil in there and things are a bit stiff, (new baulk rings etc) or have I got something wrong here? Any thoughts? All other gears click in OK.

 

 

 

 

 

2. (Oily pic from before the clean for illustration purposes). When putting the bolts back into the main bearing retainer, torquing them up fully served to strip the thread in the gearbox casing on two bolts. Bugger! Should I really look to tap new threads and use bigger bolts? They are held in there by the lock washers but can be moved with finger pressure.

 

Since one of the bolts was omitted on later gearboxes anyway, is it so important?

 

 

Thanks!

[jonlad]

I asked similar questions a couple of weeks ago

 

http://www.theminifo...rebuild-checks/

 

Hope that helps

[jonlad]

Are you sure its the thread that's stripped? Mine bent the bearing retainer because the locking plate for the other shafts wasn't there... and it felt like the thread stripping through the torque wrench

[Spider]

Item 1 sounds like a worn selector fork. If it is, you'd be very wise to replace it at this point so as it doesn't jump out of gear.

 

Item 2. If it's just the top bolt at the 10 O'clock position that's stripped, you can leave it out or Helicoil it.

 

They omitted the bolt, or rather the hole on the later gearboxes as drilling this hole here make the case very weak. I've got quite a stack of them all cracked here.

 

On that, I would highly recommend if you have not done so already, pop the bearing retainer off again and have a good look at all the bolt holes here for cracks.

[rich2]

Thanks for the tips. I will check those things. One thing I noticed in jonlads thread: is it possible to assemble the synchro hubs the wrong way round? I had mine to pieces to clean them out, but I assumed they were symmetrical when I put the back on.

[Rorf]

Yes it is possible to have the inserts of the synchro hubs in the wrong way round. You mention two bolts appear stripped - follow Moke Spider's advice

[Spider]

As Rorf said, yes, it is possible for sure.

 

However, I can see your outers are the right way around and while the inners can also be reversed, you won't be able to assemble the gear train back in to the box as far as you have gotten, at the very least, 2'nd or 3rd (or both) will drag to the point of lock up if you have these reversed.