What about the 1st/2nd selector hub. Is that sitting in the selector fork or on one side of it?

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1963 Morris 850 Smoke Grey
1963 Morris 850 Shadow Blue
1965 Morris Mini Smooth Van
1966 Morris Mini Van
1969 Morris Mini Deluxe Resto
5/72 Clubman Gt

The synchro hub was definatly sitting correctly in the shifting fork.

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It's almost as if I'm not getting enough counter clockwise rotation of the selector rod. I will disconnect it and see if I can rotate it around enough to get it in neutral....... Pos

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Is it out of the car or have you fitted it all back up?

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1963 Morris 850 Smoke Grey
1963 Morris 850 Shadow Blue
1965 Morris Mini Smooth Van
1966 Morris Mini Van
1969 Morris Mini Deluxe Resto
5/72 Clubman Gt

The hard one

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Always check you can get all gears, before bolting the motor on and refitting to da car...

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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.

Are you sure you fit the selector hub in the right way around? The're not symmetrical.

I've hit a problem, How do I get (I think it's 2nd and 3rd) off the shaft?

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Respect mine and I'll respect yours.

Read the manual, it would be detailed there.
Both gears are held in place by a splined thrust ring, which is located by a spring in the shaft and a plunger pin (2 plungers in 2nd).
You need to push and hold the plunger in with a tiny screwdriver, and turn the ring until the splines line up.
For 2nd gear you do this for 1 plunger, then push the other plunger in and turn the ring further until the splines line up.
When the splines are aligned you lift the gear upwards with the ring, the plunger(s) will slide thru the gear then boing! out. Do this last step in a plastic bag so they don't go into orbit.

Reassembly is the opposite of removal, squeeze the plungers together and slide the gear down. Then you need to push the plungers in to fit the ring. Some 2nd gears have 2 holes in them to make this easier.

Why are you removing the gears? it's only needed if a gear or the shaft is damaged. The needle bearings inside them are seldom worn.

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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.

There are some videos on youtube that go through the process of assembling the gearboxes. They start with this one:

https://www.youtube.com/watch?v=tsOJPemcEDc

There don't seem to be any on dismantling them though, which is actually more difficult if you don't have the right tools

that job is best done on your own... I was doing my mates gearbox and he was trying to help me do that bit, after 15 minutes I had to send him out of the garage, once he was out of the way it took me 5 seconds

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did I tell you that I won a trophy?

It's a PITA, but you normally don't need to do it anyway. I only did it to replace my 2nd gear to try and fix my crunchies.

I was a bit reckless (and un-informed) when removing the pinion nut and ended up snapping a tooth of the laygear and one of the gears on the shaft.
I have watched those videos on youtube and read a bit in the manuals but wasn't sure if I had come to the right conclusion.

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Respect mine and I'll respect yours.

Ah! Had to have a laugh at that. I have a good mate that gets me to work on his house and than totally insists on paying me over the top for it. But fair dinkum, if he didn't insist on helping, I'd get the work done in half the time, seriously.
Ok, back to gearboxes.

Ouch. I have heard that there is a risk of breaking teeth when taking them apart, even when you do it by the book. Standard procedure is to disable the selector and engage two gears at once (1st and 4th I think - but check the manual first, more likely to break if you select the wrong one). Then you can take off the nut.

Probably cheaper to pick up a second hand gearset than getting a new laygear. The laygear usually doesn't wear much - so long as nobody has snapped the gears off