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PostPosted: Sat Jan 11, 2020 12:16 pm 
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Location: Newcastle
timmy201 wrote:
Looking good Joe, you'll learn a lot rebuilding the gearbox! The Haltech will be a great bit of gear, hopefully once it's tuned it'll go really well and have a good cold start


Thanks Timmy - learning a lot already and enjoying it. Spent a couple of hours in the garage this morning with a coffee and and a tutorial video from Classic Mini DIY on the reassembly. Awesome content for anyone who hasn't checked it out made by an honest and modest enthusiast.

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I could only get so far while I wait for the 1st/2nd Synchro hub replacement part to arrive. Selector forks and reverse gear installed in the casing, and half of the main shaft assembled with new bearings after a deep clean of 43 years of schmutz.

After reassembling the 3rd/4th synchro hub I thought i would see how it felt with new springs going back and forward from it's respective seats. I learnt pretty quickly to be careful when doing that as I shot a bunch of springs and ball bearings around the workshop. Good thing I knew I was going to do this and bought extras!

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PostPosted: Sat Jan 11, 2020 12:26 pm 
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I can also recommend the videos by minimania and guessworks. Also having a gearbox guru around the corner helps (thanks Justin!).

You’ve got a centre oil pickup too?

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PostPosted: Sat Jan 11, 2020 1:15 pm 
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Some more info here, although mainly for a 3 synchro box - viewtopic.php?f=2&t=97472&p=1037989

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PostPosted: Sat Jan 11, 2020 3:18 pm 
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Joined: Wed Jan 19, 2005 1:52 pm
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you are going to clean the gearbox case aren't you?

EDIT: Use 5 Star degreaser and a brush. It will come up like new.

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PostPosted: Sun Jan 12, 2020 5:30 am 
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those cracks in the centre web look worrying...

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PostPosted: Sun Jan 12, 2020 8:35 am 
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TK wrote:
you are going to clean the gearbox case aren't you?

EDIT: Use 5 Star degreaser and a brush. It will come up like new.


Yep I did notice that it could use a clean with a wire brush. I had already hit it with a high pressure hose and degrease but it has since come up slightly better after some wire wheel-ing. I am not worried about anymore schmutz that's embedded in the pores of the casting.

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9YaTaH wrote:
those cracks in the centre web look worrying...


hmm. Perhaps - but in my mind this is just the quality of the casting back in the day? There are no cracks along the middle of the center web. I can't see any cracks that look like fatigue cracks. Happy to be proven wrong by the SMEs though. Let me know what you guys think!

back side
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I am unsure what those grinding marks are though???

front side
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PostPosted: Sun Jan 12, 2020 10:51 am 
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I just used 5 Star and a old stiff paint brush. Gets the casing like new. I'd be looking at another gearbox case anyway.

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