2nd and 3rd gear removal.
Turbo Mini Forums

How do you get the 2nd and third gears off the shaft, I found how to put em on, but dont want to butcher them getting them off.

My Haynes doesn't have any info on gearbox stripping, which version does??

Terry

website:- http://www.terryhunt.co.uk

the metro haynes has good gearbox coverage

"Turbo's make torque, and torque makes fun"

"did you know you can toast potato waffles?"

Metro Haynes manual is the one you want.

Not quite, the newer Haynes manuals don't have the g/box strip in them, only the older ones do.

the one with the red cover i believe

Just talked to my mate who has done a lot of Spridget gearboxes in his time, he says unless you have reason to think the bearings are shot leave the buggers on they rarely wear and they are piggies!!

Terry

website:- http://www.terryhunt.co.uk

This is a transverse engine sharing the engine oil and all the crap that goes with it

Spridgets are inline and the gearbox has its own oil

Id be pulling the lot apart to be sure. Its no good half guessing it

Yeah, good piont but looking at the leyshaft bearing surfaces and the top hat surface etc they are perfect, even the baulk rings look fine.

Having said that I'll probably get bored one night and pull em off anyway!!

Terry

website:- http://www.terryhunt.co.uk

From memory you need to push in a pin and then rotate the locking ring that secures the gears on the mainshaft. Its been a while since I last stripped one. Turbo Hogster will be able to answer this for sure as he does gearboxes regularly.

it can be a twat of a job, removal is easier than refitting.

double check the gears first, minamal side ways movement is acceptable ,

but the do wear but not as much as other bearings, good indicator is to check the gear teeth on the gear and corresponding layshaft gear and micro pitting is a good indicator of worn gear bearings.

always looking for them bigger bunches of bannanas

Unless your going to replace the needle roller bearings under the gears than I wouldn't bother.

Make sure you source replacements 1st as they are getting tricky to find and are fairly expensive (cira £60 for the pair).

As others have said, if it all looks good you should be ok!

Alex

AlexF

I have removed them just of the fun of it to check/clean. Most of my boxes have had the same bearings fitted back in. Only exception is when the mainshaft has signs of wear or broken bearing surface. In that case the gears/bearings/mainshaft is crap.

To remove find a suitable thinbladed screwqdriver, locate a plunger inside the mainshaft splines/locking ring, press the plunger in and simultaneously turn the locking ring so that the teeth og the ring line with the griives of the mainshaft. The try to slide the locking ring along the grroves (tricky to center/line) and off it comes. Check that the plunger does not disappear into the confines of the garage. 2nd gear has 2 plungers, 3rd gear only one. Or vice versa...

As I suspected I could not resist taking them off..

Front gear with one plunger was easy, just push the pin in and use a punch or something in the little hole and rotate the ring one "tooth" till they line up, I then used a very small pair of pliers in the hole and outside of the ring to jiggle it out.

Rear one with 2 plungers was not so easy! first part was the same, because the two pins are slightly mis-aligned you just push one pin in and rotate the ring with the ground in groove until the ring stops on the other pin, then the fun starts you push the second pin in and rotate the ring just a tiddly bit more until both are held out and the "teeth" line up. Like most people I suspect on my first attempt I pushed the ring too far and the first pin clicked back in, and the second attempt. So I pushed a little piece of wire into one of the gaps which stopped the ring going too far.

The next bit I felt was the hardest, you have to align the "teeth" EXACTLY and give the gear a light tap to get the ring moving, If it doesnt move first tap then align it again ...and again ...and again
It comes off eventually!!

Pics below may help

Edited by Turbo Tel on 10th Mar, 2008.

website:- http://www.terryhunt.co.uk

thats the easy bit getting them back on is a bit more tricky

always looking for them bigger bunches of bannanas

Now you tell him .... LOL

A pig of a job this ..... I hate paying for somebody to do something I can do myself. That said a FULL gearbox rebuild trys even my patience.

Anybody want to tout for my gearbox rebuild job???????

Every day is a school day ...........

How fast and how expensive ...... the same question...

I done my stripdown of my box for the 16v yesterday and the removal of those gears was the worst bit of the whole job. Having said that i am glad i done it as the diff output bearing fell apart as i took the side cover off!!

Yeah

Thats what my mate said, getting them on is trickier. Though I must say I think rebuilding this box is much easier than the TR5 one I did a few years ago, less fiddly bits but boy did you have to whack it to get the main bearings out!!

On another note I noticed that one of my shafts has a thicker shoulder (where both gears bear on to) than the other. I plan to use the thickest but is there a spec for that?

website:- http://www.terryhunt.co.uk

i dont remember thinking that it was particularly hard a job, though i did regret using cocktail sticks when one slipped and stabbed me in the finger by about 5mm

time for a cup of tea with 3 sugars

Well I just put them back together and It took all of 2 mins.. I used 2 small allen keys, one I pushed with my ample gut, the other I pushed with my left hand and my right was free to jiggle the ring into place.

So I would say getting them off was far more difficult!

website:- http://www.terryhunt.co.uk