Rebuilding Gear boxes
Turbo Mini Forums

I would consider myself relativly capable at assembling things. I also don't like spending money.

How hard is it to strip and rebuild a gear box? I've got two that need doing and I've never been a fan of paying people to do things that I am capable of doing myself.

Is there anybody in the South/West Yorkshire area that would be willing to teach me (don't mind paying for leasons).

Add me to that list and we've got 4 gearboxes in total that need to be worked on!

If something is worth doing, it's worth doing half of.

Wrong part of the country but they are not that difficult.

You need a couple of "special" tools (large circlip pliers and the large 1 1/2" socket) and there are a few "tricks" that make life easier that come with practice/experience but, we all have to start somewhere...... give it a try.

There will be plenty to help with advice even if they are not actually there.

Schrödinger's cat - so which one am I ???

They are not that hard really, I've done plenty. If you have a knackered or unwanted box why not have a go at dismantling it.

Do exactly what the Haynes says and you can't go wrong. Thats what I did first time and now they are very easy to me.

Paul

I seriously doubt it!

the only problem your likly to fall into is having sbaulk rings that are too snug on straight cut gears, in which case uust use second hand baulks.

I did it and I am a technoob. The dificult bit for me was pressing the pins that lock on the collar that retains the 2nd and 3rd pn the shaft, but I got it done.

Thanks for the advice. One is a standard box for the van. I only drove that box to the MOT station and back seemed OK. Should just want a different CWP.

My other is my JKD box which needs stripping, blasting and then rebuilding with a different diff and CWP. I know the diff is a piece of cake, but not sure about the rest.

Like you say, theres only one way to find out.

Is the 1 1/2" socket the same as the ball joint socket??

Schrödinger's cat - so which one am I ???

Build it to the book. Make sure you get spare synchro hub detent balls and springs for your first one though, as if you are un prepaired, the balls and springs will end up on the other side of the workshop. I tend to wrap them up in a rag when dismantling the synchro hubs.

Take several pitcures so you can reffere to them when re assembling, it is possable to fit the synchro hubs round the wrong way and then wonder why its not all going back together well. The difference in orientation on third/ fourth synchro is subtle.

Buy yourself the plastic third motion shaft bearing removal tool, at MITP this week end. Buy a decent pair of LARGE circlip pliers. Buy a battery terminal puller from Machine mart. Buy a slide hammer and make an adapter from an old main shaft or first motion shaft nut.

That is pretty much all you need to strip and rebuild a gearbox without the stress. These tools are not expensive and once you have them, you can rebuild gearboxes whenever you wish.

when it comes to removing the mainshaft or first motion shaft nuts I bolt it down to the work bench upside down, or bolt it down to the garage floor with achor bolts.

I saw the tools Fast Carl uses for the likes of those nuts, along with the CV joint nuts, and, it was obvious really. It was a long piece of box steel with a socket welded onto the end, simple but effective. Im going to make me one of those

If you come across problems, there are plenty people on here who are happy to help.

Edited by Sprocket on 14th Aug, 2009.

Schrödinger's cat - so which one am I ???

and remember it cant go back together if its wrong. if it does go in, you cant be far out.

I'll give it a go then

I've got a slide hammer, all be it a crap one, and I also have one of these:

http://www.machinemart.co.uk/shop/product/...-bearing-puller

How large is large for circlip pliers, I have a box set with a few sizes and ends in it. Not that I can find them in my tip of a garage!

I'll pick up a syncro tool on Sunday. I think I'm of to get a beer and stick my head into the haines book.

Thanks for the advice!

Thats the fella. use that to remove the first motion shaft support bearing ( nose bearing to some)

Forgot to add, 6" circlip pliers - don't waste your time. 8" - much better, but 12" makes it a piece of piss

I tried that once, just pulled the plastic bearing apart....

i found the gearbox really intimidating but after me and Steve rebuilt mine i felt all geared up by the end

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others got here first!
so your starting spread shoult be about 1/2 inch i think. open to opinion though, its been a while.

too small a pliers, and you risk it slipping and ruining the outward edge of the holes, but if so, it can go back in in reverse for next time. if the bearing edge is not too bad.

defo use the undo nut method to take off bearing. takes it off nice and straight. plus skipping a step in plans

Edited by 1972-ANGUS on 14th Aug, 2009.

Groan!

So the first thing I need to do is clean my garage and gets some clean pots to put stuff in

On 14th Aug, 2009 apbellamy said:
So the first thing I need to do is clean my garage and gets some clean pots to put stuff in

Schrödinger's cat - so which one am I ???

lol

I'm trying to make more room - somebody by my clubman!

I haven't actually rebuilt my gearbox yet, but this article by Guessworks seems quite good and has lots of photos...

http://www.theminiforum.co.uk/forums/index...?showtopic=9808