hi, is it's hard to do a DIY gear box rebuild because i have lost two teeth on a gear and i can get the parts to replace the broken gear, but will be a super hard job or just a simple pull apart and replace job.

thanks

Its not a job for a beginner. Pulling them apart, replacing worn parts and re-assembling isn't that difficult, but there are a number of areas where tolerances and clearances need to be measured and the appropriate shims fitted. I'm happy to tackle pretty much any job on a Mini, but I prefer to take my gearboxes to an expert.

There's an article in the current Mini magazine about it at the moment. Have a read and see if you want to give it a go.

Tim

I'm doing my first ever gearbox at the mo. Armed with Haynes early edition, KC's Mini Expert and the wealth of information on here and its not too difficult. Unless you get things like the pinion nut locked on with Loctite Then you discover its not the sort of box you thought it was after you have already bought the kit and it's cheaper to buy another gearbox instead of a different kit

But it's all a learning experience

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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!

hi, thanks for the reply. what kit are you talking about and what book do you have to read off

I got the full kit with diff parts http://www.minispares.com/Product.aspx?pid=37735 There is one without diff parts. Cost about $450 landed.

The 1st (and/or 2nd) edition Haynes Workshop Manual has the pull down and rebuild of the gear box described and illustrated with photos. Later editions removed the section completely. Keith Calvers "Mini Expert" (discussed elsewhere in this forum) gives a very good coverage of the gear box. I had a friend bring me a copy from England - it would cost about $30 to have one posted (5UKP for mag and 6UKP for postage)

Plus the Dr and others on here have been very helpfull - in discussion threads, PMs and phone calls (thanks guys)

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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!

hi wombat
Do you need any special tools for the rebuild? appart from feeler gauges and the like?
I am going to do this for myself in the near future. Was there anything else you required other than what was in the kit?. Thanks mate

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There's three steps where you need special tools. The good news is you can make them yourself 1. puller for the first motion/input shaft bearing 2. spacer to remove main centre bearing 3. jig or frame to lock up casing to remove main shaft/pinion nut (or you can use impact wrench, i believe). The long reach socket for this nut you will have to buy/borrow

Gearbox o/hauls may appear daunting at first, but the books mentioned are good (also Jim Tyler's) and once you have done one, you will feel pretty smug And you will then appreciate why exchange boxes (good one's) cost, because of the labour involved.

lastly, there's plenty of help on tap right here on this forum, if you get stumped.

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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.

Thanks mate,
In appreciation for all the help I "may" need I will take lots of photos and possibly compile a how to. I will present it to the forum for refinement so it could then "possibly" become a sticky. This topic has been mentioned millions of times and the infamous mini gearbox rebuild makes most of us cringe. So It would be good to have a cheaper DIY option.

Cheers

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If you havn`t spannered on lots of cars stuff before & if you fumble your way around tune up stuff like cabs & distributors & you havn`t yet ovehauled a mini cyl head & the like, then i certainly wouldn`t expect your ability to overhaul a mini gearbox to be superior to your confidence of doing same.

I`ve known many many people "try" to overhaul mini gearboxes & after "THINKING" that they`ve done a good job & after fitting it all back together & after fitting it all back into the engine bay & after hooking all the relevent things back up, they then find that they have not only stuffed the job up but also now stuffed up more than what was wrong in the first place

only a warning, so don`t bag me out,,, Ive done so many of them that i stopped & can do them blind folded, with one arm tied behind my back, in a pit of snakes & covered in baked beans (so to speak) But that`s why i`ve suggested you not do it.

ok,,, maybe not the pit of snakes thing

They`re actually easy after about the 3rd or 4th attempt but they can still catch out even the very best in the business -on rare occasions.

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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.

I think it is the bit about needing three hands to assemble the syncro hubs.
They are not a hard box to work on but they have a lot of hidden tricks.
If you have assembled a Holden gearbox you may be ready to move up to the next level and try a Mini box. If you have never done a box it can be a struggle.

After working on Fiat 124S, Alfa and VW beetle boxes, they are easy.
But.. the very 1st Mini one I did in 1965, took me a whole weekend to strip!!

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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.

Beetle boxes. You undo the back and nothing comes out! Then you find you have to pull the diff to get to the bolts. Aaaagggghhhhh!!!!!!
Give me a 10 speed Roadranger, much easier to work on. You can't lose any bits cause they are all big.

There has got to be a first time for everything The first aborted attempt at the 3 syncro box took me 3 weekends - and a few days and I learnt a few things - now when I get around to the 4 synchro box it should only take me 2 weekends and maybe some evenings

(actually I'm glad I had the practice )

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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!

Is it possible to check the basics before you bolt the engine back on? Spin the input shaft and put it into each gear to check if everything spins freely with no strange sounds? Also a description and photos of the special tools to make those described above may be handy. Please

I've done it once or maybe that should be twice.I had to pull it out again after the 1st attempt as I had neglected to change the hub springs.Th old ones were too weak and stopped me getting into 2nd without crunching.
I basically followed the manual and I did have an old gear box to look at but I did take it to a mini place to get a couple of the bearings out.
Don't scrimp on changing things and watch your tolerences.If I could do it then most people should be able to.