gavs gearbox rebuild update
Turbo Mini Forums

well gavs dropped of the boxes the pther day so now its time to get to work.
i didnt get a pic of this box before i cleaned and is wished i had because it was quiet grotty to say the least, the box is a y reg a+ item with a 2.9 diff.

it took me about 30 mins to strip to just the selectors but another 2 1/2 hours to clean the bloody thing it had 20 odd years worth of grease and grime on the out side and bad staining on the inside but plenty of elbow grease later and she came up looking good.

thats enough of the waffle now on to the build.

first up ive takled the diff after splitting her down it showed bad planet wheel and diff pin wear also these early diffs used the a series casing and not the later tagged casing, always use the later as the a series ones are shit and the casing wears as well as the thrusts.

if you do use one of these then always replace the roll pin as wella sthe diff pin, planets, and washers but how relible these are is upto the driver on how hard her drives round corners, wheel spins and quick getaways.



now all the bits are now here ready for reassembly after a clean and blow off with the airline.


i had to file out the new tuffnel washers as the inner circle was to small to fit buy a few thou.
these diff can be a bit tricky to get together but they are a nice bit of kit and are bomb proof.



here she is all done just the crown wheel to put on. both the output shafts were a nice fit with just a minute bit of side play.

now for the worst bit of the whole build removing the 2nd and 3rd gear and replacing with the sc set. any one who has done this before will no what im talking about.


here she is all done and it only took me 15 mins ( world record for but plenty of swearing never the less).



some times the gear bearings needs replacing but these were the best ive seen on a second hand box and they are like new , they is hardly any play at all.



and now for another hard job replacing the syncro balls and springs, sometimes i leave these but as gav wanted a good rebuild so they got replaced.



now both syncro have been doen now its time for new baulk rings and the syncro's put on the main shaft.

hey presto


now to test the endfloat of the lay gear she was a bit to much with the old tabs in so i found one in my stock which took her from 8 thou to 2 thou so she is nice and tight but not literly.



nest i checked the selectors for were there was a little but not enough to change them if there were bad then the car would jump out of gear this is normally second in most cases.

now its just a matter of fitting the main and first motion shaft bearings, refitting the oilcage, layshaft and gear and doing it all up tight to 150 ft lb. i cant do the first motion up yet as gavs is still waiting for the input gear of the drops to arrive, so i cant fit the diff yet either but have checked the preload as is spot on with 1 thou preload.

always looking for them bigger bunches of bannanas

I know what you mean about removing the 2nd and 3rd gear!! Some are nightmares... not all thou - weridly.

AlexF

Excellent write up hogster!

Only thing I can add is that why no central oil pickup pipe?? Every mini gearbox I have ever taken to pieces has had the standard one chucked straight in the bin in favour of a centre one......

nice one turbo hogster

nice and clean!

its on its way tom, nice write up rich so glad i got you to do it lol!

Shame the pics are broken is there anyway to fix it?

I run a supercharger and I don't care the TB is on the wrong side.
VEMS + 12 PSI + Liquid Intercooler = Small Bore FUN!

Can't see the pics

There are now also movies on youtube, for instance from Guessworks:


Also look at Minimaniavideos:

Dazed and Confused....

After SEVEN and a half years, I'm not surprised the pics are no longer there !!

Does this set a record for thread ressurection ?

Metric is for people who can't do fractions.

nope V must hold that record... I'm trying tho, you know using the search button and all... :)

I run a supercharger and I don't care the TB is on the wrong side.
VEMS + 12 PSI + Liquid Intercooler = Small Bore FUN!

Some of the Mini Mania videos have me cringing.
Why would anyone video themselves pulling a tight flywheel off using the retaining bolt as the bit to push against instead of the proper insert ?

Metric is for people who can't do fractions.

Overall they seem to give a good visual on how to do stuff, there are some corners cut, like not torquing up the gearbox bolts and just using a windy gun, but they still helped.

I run a supercharger and I don't care the TB is on the wrong side.
VEMS + 12 PSI + Liquid Intercooler = Small Bore FUN!

Overall they seem to give a good visual on how to do stuff, there are some corners cut, like not torquing up the gearbox bolts and just using a windy gun, but they still helped.

I run a supercharger and I don't care the TB is on the wrong side.
VEMS + 12 PSI + Liquid Intercooler = Small Bore FUN!