I've removed the layshaft, both main shaft bolts and the circlip, but am unsure how to remove the motion bearings so that I can remove the main shaft. What's the trick?

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1998 Rover Mk VII
2001 Honda CBR 929RR (street)
2014 BMW S1000RR (track)

The outrigger bearing or the big ones in the gearbox?
I use a small puller for the out rigger and a slightly bent brass drift to knock the other ones out.

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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

Brian - in case you haven't seen them there's a few threads in the How To section on gearbox work, including bearing removal.

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ex-NSW Police 1970 MK II Cooper S
VMCI #43

the workshop manual gives details...

you need to pull the 1st motion shaft out (I modified a slide hammer to work as a puller) and then you can gently drift the main shaft to push the double row bearing out (pieces of split exhaust pipe between 1st gear and the bearing). Once that's out the mainshaft will come out easily if you hold your tongue right

expect the synchro hub ball bearings to go flying

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did I tell you that I won a trophy?

Another option, not tried it but may be worth a go. This is a US site so guessing they mean 300 degrees Fahrenheit or 148 degrees C, not 100% sure through.

http://www.minimania.com/part/AAU8424/B ... ini-Cooper

"An easy way to remove the old race is to clean the housing very well, remove the circlip, and place the whole housing in the oven at 300 degrees for 10 minutes. Upon removal, slam the housing, engine side down, onto a flat piece of wood and the race should fall out. This is also a good time to install the new outer race. You can freeze the new race to make it that much easier."

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1972 Leyland Mini Clubman
2000 Honda CBR929RR

Thanks for the reply guys. And yes Winabbey, I have certainly bookmarked and read your awesome transmission build scans. I must've skimmed over the quick word about removal, and it still doesn't sit too well with me. ("...once you've knocked out the 1st motion shaft bearing with a drift...")

So, using this diagram for clarity (as it has nice numbers pinned all over it).. http://www.miniclassics.co.uk/mg/pages/info1.htm

The "First Motion Shaft" is the piece labeled #1 & #2. I can't see any way you might get a drift in between the trans case and the bearing, but maybe I am missing something.
The other thread shows a piece of square steel with a slot cut in it, but I am missing something here as well. The bearing is in the case, with a shaft coming through it. How would I "slip this over the bearing". And even if I did, winding in that bolt (from the photo) would only push the first motion shaft further inwards. Perhaps the bolt is there for illustration only? And the welded bolt is the correct size to thread onto the first motion shaft?

So far the only suggestion that seems to make sense is Simon's. It sounds like I put the bolt back onto the first motion shaft, attach a slide hammer, and start drifting out the bearing. This sounds to me like a lot of force and potential damage to the first motion shaft. But if that's the way to go..... Just say the word and I'll start slide hammering away.

Sorry for the ignorance, I don't know why I'm having such a hard time wrapping my head around this one.

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1998 Rover Mk VII
2001 Honda CBR 929RR (street)
2014 BMW S1000RR (track)

Since 1965, I have just undone the big 1st motion bearing circlip, then with the pinion nut off and the 1-2 and 3-4 detent spring plugs removed (non rodchange boxes), you can use a brass drift on the mainshaft end to drift the 1st motion shaft & bearings out. The big bearing is not a very tight fit in the case.

ps @Simon K, you don't lose yer synchro balls if done this way, carefully!

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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.

Doc, you're saying actually drift the entire mainshaft - as in - place the drift against the slotted end where the speedo gear would go, and whack away?

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1998 Rover Mk VII
2001 Honda CBR 929RR (street)
2014 BMW S1000RR (track)

Yes that is correct. It moves easily. I have never had to warm the case up.
It doesn't hurt the mainshaft nose needle bearing, either.

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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.

http://www.theminiforum.co.uk/forums/to ... with-pics/

This might help

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1972 Leyland Mini Clubman
2000 Honda CBR929RR

I like this method the most. I'll let everyone know how my non-trained non-doc hands work it out.

Thanks everyone.

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1998 Rover Mk VII
2001 Honda CBR 929RR (street)
2014 BMW S1000RR (track)

That's a good one too! Didn't find it in my searching. I'm very curious to go home and look at my gearbox, the way he has the drift against the first motion bearing looks too easy! I swear I don't have that kind of clearance in my case.... I hope I'm wrong. I'll see if I can drift it out from just the one spot (drifting on only one side tends to put it at an angle and wedge it in worse?). If that doesn't work, Doc's method is the go.

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1998 Rover Mk VII
2001 Honda CBR 929RR (street)
2014 BMW S1000RR (track)

I don't like that method, you can cock the bearing- whereas my one pushes it straight.
That notch in the case is to let the mainshaft clear it during assembly, not to bung a pin punch into.

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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.

My thoughts exactly. Thanks Doc.

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1998 Rover Mk VII
2001 Honda CBR 929RR (street)
2014 BMW S1000RR (track)

Well, Docs method worked beautifully. It didn't take mush force at all to drift the first motion shaft out, and then after sliding the selector hub over I was able to get a punch in on the top of the double row bearing, and on the bottom of the bearing via the diff housing hole. It also came out without much force.

From there I was able to completely disassemble and clean the lot! Next week I'll be tearing down the diff, and then all the big parts go off for hot tanking. This is the most fun you can have without boobies.

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1998 Rover Mk VII
2001 Honda CBR 929RR (street)
2014 BMW S1000RR (track)