When I pulled the 3 synchro box apart the main gear cluster required deliberate dismanteling. When I pulled the 4 synchro cluster out it literaly fell to pieces ( I was lucky to catch the balls and springs)

Which is normal? Should I be looking for a problem?

_________________
David L


My greatest fear in life is that when I die my wife will sell my Mini and tools for the price I told her I paid for them!

sounds like you have major 4speed problems David

_________________
No offence intended here but--> anyone writing a book about minis 30 years ago may not have experienced such worn or stuffed-with components as we are finding these days.

You should put your heart & soul into everything you do.

In what way and what should I be looking for?

_________________
David L


My greatest fear in life is that when I die my wife will sell my Mini and tools for the price I told her I paid for them!

Relax Dave, it's normal for the synchro hub balls to fly into orbit when removing the mainshaft. I think some books advise you to cover the top of the box with a cloth to avoid the necessity of scouring the whole garage floor for the missing balls & springs.

You've done good.

_________________
1967 Cooper S - new front bearings to do.
1965 Cooper S shell - Slow progress. No time or money!
1966 Deluxe- next rustoration!
Mk 2 & XJ6 Jags. Less said the better.

You can get the synchro hubs and sleeves out as an assembly without losing yer balls but it needs forethought...
remove the 2 detent plugs in the bottom of the box first, so the selectors & forks can slide with the mainshaft.
I hope you used the special service tool `XYZ' to remove the mainshaft bearing... Matt knows what this is.

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.