How do I remove the second and third gear from the shaft?

This is the link for you. I found it pretty invaluable when pulling apart my gearbox. Wombat was kind enough to put me onto it. It's the opposite way around (assembling) but is pretty good for what you are doing.
Pictures speak a thousand words!

http://www.theminiforum.co.uk/forums/in ... hl=gearbox

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SooperDooperMiniCooperExpertEngineering

All garage work involves equal measures of enthusiasm, ingenuity and a fair degree of irresponsibility.

you depress the plungers under the lock ring and then turn the lock ring till the splines align and slide it off. There is one plunger on third and two on second.
I find the best way is to put the mainshaft in a vice with soft jaws and only lightly! and then use a sharpened jewelers screwdriver. And then use a pair of cir-clip pliers to spin the lockring.
It is one of those frustrating jobs with the mini. Just wait till you have to get them back together though the same can be said about the synchro hubs

Synchro hubs are easy, I made an assembly tool from an old 1st/2nd synchro hub assembly. Wombat has one now too.
Stops the balls and springs going into orbit... and no hoseclamps/cable ties/3rd hands required.
I'll find a pic and post tonight.

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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.

I couldn't bring myself to put grooves in a hub (and didn't have any spare) so I made my own way and now I can do it first go in about 30 seconds. No special tool required

Someone else put me onto the zip tie method> This is where you put a zip tie around the synchro hub (including balls and springs) and slide the outer ring over the top pushing the zip tie away as it goes. It which was cheap and easy for my first box ever.

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SooperDooperMiniCooperExpertEngineering

All garage work involves equal measures of enthusiasm, ingenuity and a fair degree of irresponsibility.

That'd work well. I just dis/reassemble synchro hubs from inside a big zip-lock bag, that way if anything pops out it doesn't go far.

Here's the pics- sorry one is a bit blurry...
I made this tool because I got sick of balls and springs going into orbit.

All Mini synchro inner hubs are the same spline profile, this outer ring is an old 3 synchro 1-2 one, but it works on 4 synchro rodchange and remote as well, for both 1-2 and 3-4 assemblies.

To use it you put the 3 springs in your hub, slip it into this ring from above with the 3 angled grooves aligned with the spring holes.
Then you sit the 3 balls in there and push the inner hub down until it clicks, this pushes the balls into the holes.
Then, take the outer ring belonging to your hub, sit it on the bench underneath this one so synchro lug slots align, and push the hub with balls and springs downwards into the ring.

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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.

And it works a charm - 1st one took all of 30 seconds while I worked out what I was doing - the second one 10 seconds - practice make perfect

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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!