Started on gearbox tear down tonight (rod change) and when I removed the idler gear there is a lot of wear behind the idler gear on the face of the gearbox case. At least 1mm of wear plus some deeper scrapes in the case. Any ideas on how to fix this or am I better off looking for another gearbox case?
Thanks.

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1963 Morris 850

You can get oversize shims / thrust washers, but there is a limit. Also will depend on your transfer case gasket thickness, there a three different sizes floating about!

Cheers Shane

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If it's not a Cooper S, the mini was designed to be modified!

Assuming there is no more than 1mm of wear on there, you could remove all the studs, clamp the box level on a milling machine and machine the gasket face and the idler gear boss flat.
Alternatively you could just machine the idler boss flat, and get a toolroom to make up a thicker thrust washer. This must be hardened and ground... design as per the originals.

Personally if wear is more than 1mm I'd be looking for another case.

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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.

Might be easier to get another case then.
Thanks.

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1963 Morris 850

You love your milling machine dont you doc?

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The best part of fixing your mini is the test drive

Minis..

1976 van daily drive
1975 van
1968 deluxe in the shed
1967 deluxe high strung 1310
1959 austin healey sprite

I'm a machinist among other things, so yes I enjoy it. What I can't buy now I can often make. I love my Myford Super 7 lathe too...

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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.