The 4 synchro gearbox on the 997 Cooper will need some attention when I pull the engine down this November. The synchro on 2nd is completely RS and will need to be replaced. Other than that, the box is very quiet throiugh all gears and doesn't whine at all, it also has a very short throw between 1st/2nd and 3rd/4th which suggests that the change on 2nd is the exception to an otherwise good box.

I can get a complete bearing/baulk ring/gasket and seals kit and go through the box like a dose of salts, or I can perhaps just replace the baulk ring/s on their own with a minimum of other new parts.

How well do the bearings on either end of the mainshaft standup to being pulled out and replaced? Is it just not a good idea to reuse these two? Its not something that I would usually consider to be acceptable, but I am open to being told otherwise.

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SooperDooperMiniCooperExpertEngineering

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

As long as the baulk rings in the kit are ok. When I had my box rebuilt, I collected a few s/hand rings and picked the best to give to the builder because I had only heard bad things about the new ones.

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Ryan Filippi
Minis In The Gong
[email protected]
www.minisinthegong.com.au

Just to be clear here, this is an all synchro 22G1128 remote type gearbox? (I ask because the 997 was fitted with a 3 synchro box)

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Sure is. The 997 happened to come with a Mk1 S block, mk2 S head (stamped), and a 1128 gearbox

Its not going to be the engine which will be in the car in the long term.

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SooperDooperMiniCooperExpertEngineering

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

OK (funny combination for a 997)

I would suggest mandatory (minimum) replacement;-

Spigot bearing (the little one between 1st and 3td motion shafts),
Layshaft & bearings (Karcraft have very good ones ATM - their competition one),
Idler Gear bearings,
1/2 Selector Fork (if you can get one),
Syncro Hub springs,
Diff pin, sun gears and thrusts,
Speedo drive seal (and all other gaskets & seals),
1st and (of course) 2nd Baulk Rings (use ONLY genuine ones),

and check all other parts, replacing as required.

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PM sent.

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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.

Thanks all,
I've not had a problem with the Minisport (UK) baulkrings on the two boxes I have done. Skender's box is as smooth as silk. But I do have a pile of 8 of the early baulk rings.
Whats the process involved in getting them resurfaced? 20 thou off the gear side of the baulk ring? Is that all?
What are the machine shops usually asking for this to be done per ring?

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SooperDooperMiniCooperExpertEngineering

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

Send em up Mick, I do for $5 each.
They are induction hardened at the 3 lugs, so need to be surface ground or linished, not machined.
As I said in PM the early forged ones are best, but even the later ones work fine with .020" taken off. Unless they are worn out and touching the gear already.

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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.

Sounds perfect Doc

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SooperDooperMiniCooperExpertEngineering

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

Mick, I have a complete [overhauled] 997 box guts that was fitted in to a morris 1100 under a 1275 that I picked up some time ago if you find you need any other little bits when you pull it down

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Research is the difference between speculation and investment. Anyone who copys some one else will always be second
www.minisprintgt.com

Thanks David, that would be very welcome!

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SooperDooperMiniCooperExpertEngineering

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

just send the box to Kev - or deliver it yourself ( and take beer)

At least one year and counting

Cheers, Ian