Gearbox rebuild problem

[PhilAllen]

I'm part way through my first gearbox rebuild (fortunately using a spare gearbox a friend gave me rather than one from a working car), using the rebuild guide from Dorset MMOC which I've found really helpful. I've now done a silly thing though - I got to the point where all the selector rods and interlocks were back in and the guide suggests checking that gears can be selected. I did that and all was well. I was feeling quite pleased with what I'd achieved and decided to try the gears again just for the fun of it. A mistake as I inadvertently moved the first gear a little too far and the detent balls in the hub have popped up and locked the box in first gear.

The rebuild manual suggests if this happens just coax the gear back over the balls, don't force anything. I've tried everything I can but I can't get the gear to go back. What I'd like to know please, assuming someone else has also made this mistake, is what exactly do I need to do to get the gear to move back over the detent balls?

Currently I've removed the selector rods along with the 3rd/4th and reverse selector forks. The 1st/2nd fork won't come out as it's over the gear and the gear is to far to the rear of the box to allow clearance. I've also removed the layshaft so the layshaft gears are clear to make the 3rd motion shaft free to turn.

Any working methods to get me back to where I was gratefully received! I've also now turned up a washer as suggested in the guide to use when I reassemble it all again to prevent the problem next time (as well as having learned a lesson!).

[PhilAllen]

I hope it isn't bad form to answer your own questions, but I managed to solve the problem.

I'd searched before posting in case anyone had already had the same thing, but not found anything. Having made my earlier post I carried on through my search and one the 5th or 6th page of results found one that mentioned pushing the inner gear of the pair. I'd only been trying to move the outer gear under the selector fork as that was the one that seemed to be out of place.

In case it ever helps any one else - a screwdriver inserted by the 2nd gear synchromesh cone to push the inner gear backwards makes it much easier to move the outer gear forwards back into position.

Now all I need to do is build it back up again!