Hi all,

I've always had issues with my 2nd gear crunching. My double-row bearing in my gearbox failed a couple of years ago, so I thought what the hell, I'll reco the entire gearbox.

And I made the crunching worse.

Now, I've got the gearbox out again, and I'm trying to figure out what it could be. Off the top of my head, the cause could be:

- Worn baulk rings
- Worn detent springs on selector hubs
- Worn gear cone
- Worn selector forks
- Badly adjusted/ worn clutch

To fix mine, I replace all the detent springs and balls and got some good 2nd hand baulk rings, and chose the best to put in the box. If memory serves, the gap for seconds gear was a little over 40 thou - I believe that should be enough. The selector for was within the specs of the manual, but there wasn't much in it. And I know it isn't the clutch, that's been fixed as well ,and no issue with any other gears.

It was suggested that I may have got the 1st-2nd gear selector the wrong way around (since changing into first became a little harder), but I'm pretty sure that's right.

Any more ideas?

Anything? Even anything obvious. The gearbox all looks fine, but it's clearly not. Surely somebody must have an idea?

Clutch in, hold the gear lever against second gear but not engage it. You should hear the synchro (baulk ring) make a distinct whining sound to spin up the gears to match the engine speed. Is this happening with your second gear? It should do this with all your other gears.

_________________
Lillee - 1969 Morris Mini K

Hi , have you read through the old threads .If not hopefully these will help.

viewtopic.php?t=63126&highlight=

viewtopic.php?t=13866&start=0&postdays=0&postorder=asc&highlight=

Cheers :Bill

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If You have it apart, check the dog teeth on the gear they are often worn
and flared a bit, which does not help, if You have a look at the top of the dog teeth
You will notice that in groups of 4 the tops are wider if you find the first group
turn it to the twelve oclock position and you will find the rest at 3 6+9
I find that if you have a lot of wear on these
You will almost always have problems, also check for back clearance on your
baulk rings The best ones IMO are the early type like those used on the 850
Mini deluxe etc

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The Sort Of House I Lived in, Or The Kind Of Car I drove ... But The World May Be A Better Place
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Thanks for that, I'll have a look when I get the time - I haven't checked for the dog teeth. The baulk rings are good, there was over 40 thou clearance, and the gripped the cone well.

The only other thing I can think of is that the forks (which were within spec) may be only light worn on the 1st gear side, and heavily worn on the 2nd gear side. Or maybe some monkey has bent a fork or something. Perhaps?

Have you checked the 1st/2nd synchronizer is assembled correctly? You can put the hub in the wrong way around, assemble it all, and then 2nd gear synchro is do good and will crunch. The long side of the inner hub needs to be on the same side as the long side of the outer ring.

Yes, after I put it all back together, I talked to my local mini mechanic, and this is what he suggested. But I've taken the box off now, and I did it right the first time, so it's not the issue.