Hi all,
I'm almost at the end of stripping my box for a rebuild. I've removed all but the 3rd motion shaft. And actually mean only the shaft - I've removed the bearings that hold the shaft in place, but I still can't get it out!

It looks like the shaft is too far to the right (when looking from the diff side). I can't move it any further, since the 'hat' that holds the first gear stops it. I can't lift it out, because the end of the shaft hits the 1st motion shaft bearing hole. I've taken a piccie to explain:



Any you don't need to warn me of the detent springs and balls - after launching one set into the room, I put my hand over the others and took them out to avoid doing it again.

End of the shaft comes up through that nick at the top of the hole on the right

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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!

You need to remove the 3rd motion shaft bearing first.

Drift the shaft (gently) to the right, then you can just get a drift in to knock the bearing to the left, but you'll only get it a short way. I have a special thing-a-majig to get it out the rest of the way. You can make one if you have an old bearing and an angle grinder.

Then you can lift out the shaft as wombat says ^

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As GT says you need a spacer to knock the 3rd motion (main output) bearing out to make room so you can get it past the "nick" - it still wont be "easy".

Don't be tempted to go bashing on the nose of the mainshaft to get the bearing out - you can damage a lot of stuff that way that will cost extra $$ to fix.

cheers,

Jacob

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'72 Clubman Van - 1022cc, 295 head, 731 cam - Daily Driver
'69 Morris 1100 S - Dinged by a bus, in shed under repair
'64 Morris 1100 - Early 1100, long term project

I've already removed the 3rd motion shaft bearing (in fact, you can see the two spacers I used to the right of the gearbox) - but the shaft is still a little too long to get through that notch.

The picture there is without the bearing, and as you can see, the shaft will not clear the housing on the right. Does the hat that the first gear sits on move? All I can think is that something has shifted along the shaft somewhere, stopping the 1st gear from moving any further right.

Without labouring the point - have you pushed the cluster to the left as far as it will go - then the left end down while lifting the right hand end - the shaft is a very snug fit through the nick.

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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!

Keith Calver's Mini Expert gives a good coverage on how it's done - you can Download from http://www.minimag.co.uk/ according to his web site.

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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!

Thanks guys, I've got it out!

I made sure the cluster was as far left as possible, and it still didn't fit, but I noticed that the selector hub couldn't actually reach 1st gear. So I did exactly what VulcanBB18 told me not to do and bashed (tapped!) the mainshaft. It seems that the hat that holds the 1st gear had moved to the left.

And another question: to get the selector forks out, do I drift the pin out the other side, or is there a magic way of removing it from the top?

Tap the pin out with a pin punch the right size.

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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.

Irrish yobbo,,, im not trying to be rude or degrading in any way whatsoever,,, just trying to make sure you get it right before it`s too late

but if you`re having difficulty working out how to get a mini box apart then i can only suggest that you "Please-please-please"" get someone who has done it 500times already to help you put it back together,,, there are so many things that can & will bite you & you will only find out after the box has been fitted to the engine & the engine fitted into the car.

is there anyone who knows mini boxes near you who can help???

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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.

Thanks Miniman, I know a few people who have offered to help me who have done this before, and I will be giving them a call if (when) I have any trouble.

I've done plenty of research into rebuilding the box, but there seems to be less on dismantling it. I'd rather ask here than try something and stuff it up, and I won't be doing anything unless I'm sure it's right.

But thanks for your concern - you're right, I don't want to fit it to the car and then find out something's wrong!