Morris Minor Owners Club

Thanks Mike,

The only thing that worries me in a gearbox is the magnet coming adrift , I did think about blind drilling the plug from the outside and glueing it in a couple of mm below the surface.

All the parts tp re-build it are here, and I've been going though all the parts to re-use, only issue I have found is the rear bearing carrier, firstly it has this damage that looks like it has been hit with a punch.
And secondly with the alighnment peg matchong the rear case the cut out for reverse dosen't match.
Fortunately the one from the second gearbox aside from needing a clean is in good condition and lines up perfectly.
No idea how this could be wrong unless they changed they position of the peg at some point and the wrong part has been fitted.

started putting it together today, using the bbq heated up the front bearing and it dropped straight on, washer then tab washer followed by nut done up as tight as I could holding the shaft (need to go and get an old clutch plate from my lock up to finally tighten both nuts).
For the rear one heated the bearing carrier up and dropped the bearing in with the circlip in place,
6
the heated the assembly up put it on the 3rd motion shaft with a spacer shim followed by another spacer shim, the tube, speedo gear, washer, tab washer and nut.
a couple of issues though, while wiping the rear synchro hub over it spring apart, found 1 ball and the 3 springs but 2 balls are still AWOL, used the ones out of the second assembly to put it back together with a tie strap, one tip for anybody else doing this, make sure you get the one flattened off spline in line with the plunger otherwise you won't get second gear (so I ended up doing it twice!).

that was relatively quick to fix, the second issue came about when I went to fit the reverse gear shaft lock nut, the thread in the case is stripped, looks like it has previously been bodged with chemical metal or something. So I have 2 choices either fit a helicoil or clean up the second case but then it's likely the shim I have bought for the layshaft won't fit, I've ordered a helicoil because I suspect it will be here before I get round to cleaning the case anyway.
So for now all work on it is stopped.

In the end I bit the bullet and cleaned the second case up reverse idler is in OK, unfortunately it does need a thicker layshaft shim, the one I have gives a snug 0.1mm/ 4 thou clearance, while you could probably get away with it what's a few days to wait until it's spot on clearance next one up is now ordered.

thought about this yesterday evening and remembered I had the other front thrust washer, so today I measured that, and it is around 2 thou thicker than the one I was using, this means I now have a gap of around 2 thou, I reckon I can carefully take 1 thou off the back shim with a diamond stone to give the required 3thou clearance, after 10 minutes or so I had taken 1/2 a thou off but my fingers were freezing, so another session in the warm in the kitchen this evening should see this sorted.