Gearbox Refurb 2014/15

<This post is part of the 'Winter Project 2014/15 - New Engine Rebuild' project>
For updates, stick a 'Like' on Wayne's Mini Progress facebook page.

The years winters project was to totally strip, recondition and rebuild a 'new' engine, so it only seems fitting to give the gearbox the same treatment.

I have a selection of 3 gearboxes to choose from, thankfully all the same type. Each has it's own problems and merits, one had a very good case, another a good diff and the third has the better looking gears.

So this project is to take all these 'better' parts from the three gearboxes and bring them together with some new parts and make a 'new' gearbox to go with the 'new' engine. At some point, the other two 'left over' gearboxes will get rebuilt and hopefully sold on to make a little cash.

Overall the project took me nearly 3 month working in my spare time with little to no experience, so if I can do it, anyone can!...


Friday, February 23, 2015
Differential Stripdown
Differential Stripdown


Starting with the differential. I managed to strip the 2 diffs I had and cherry picked the best of the bits for a rebuild.





Friday, February 23, 2015
Gearbox Stripdown - Part 1 - Getting Started
Gearbox Stripdown - Part 1 - Getting Started


Time now to get the gearbox to pieces, check it over and see what we have. One step at a time of course! Let's start with part 1.









Wednesday, March 4, 2015
Gearbox Stripdown - Part 2 - Gears Out
Gearbox Stripdown - Part 2 - Gears Out


Work on the gearbox continues as the correct tool arrives and all the internal components are removed.









Thursday, March 5, 2015
Gearbox Stripdown - Part 3 - Selectors Out
Gearbox Stripdown - Part 3 - Selectors Out


The last of the gearbox parts come out of the gearbox.







Friday, March 6, 2015
Gearbox Stripdown - Part 4 - Mainshaft Strip
Gearbox Stripdown - Part 4 - Mainshaft Strip


With all the parts out of the gearbox, the mainshaft is stripped down and checked for wear.






Saturday, March 7, 2015
Gearbox Rebuild - Part 1 - Selectors In
Gearbox Rebuild - Part 1 - Selectors In


Wooo Whooo! Finally the gearbox rebuild can begin, by getting the selector forks in place along with the reverse gear and the oil strainer.






Saturday, March 14, 2015
Gearbox Rebuild - Part 2 - Mainshaft Rebuild
Gearbox Rebuild - Part 1 - Selectors In


Seemingly a complex job, but as it turned out, it was fairly straight forward, as long as you know how!






Sunday, March 15, 2015
Gearbox Rebuild - Part 3 - Gears In
Gearbox Rebuild - Part 3 - Gears In


The gears finally get reunited with the gearbox.







Wednesday, March 18, 2015
Gearbox Rebuild - Part 4 - Finishing Off
Gearbox Rebuild - Part 4 - Finishing Off


Bolting the speedo housing and the oil pickup pipe in place finish of the gearbox rebuild.







Friday, March 20, 2015
Differential Rebuild
Differential Rebuild


At last, after a months work the differential unit is rebuilt and bolted back on the gearbox. It's been an epic learning process, but all good things must come to an end at some point.






Wednesday, May 1, 2015
Idler Bearing Removal
Idler Bearing

After an initial setback in this post here, both the idler bearing in the gearbox and the transfer housing have finally been extracted and are ready to be replaced. Getting them out taxed me to the limit of my problem solving abilities, but I got there in the end.






Friday, May 8, 2015
Installing New Idler Bearings
Installing New Idler Bearings


The last piece of the puzzle is to install the new idler bearings, but like so many other things, it's never that simple or straight forward!









And that's all there is to it really! It only took me 3 months to do!
It was a ton of work, but it's sorted now and I'm glad I spent the time doing it as I now have peace of mind that the bearings and baulk rings have been replaced and should, hopefully, be trouble free for many years to come. Let's hope so!


<This post is part of the 'Winter Project 2014/15 - New Engine Rebuild' project>
<Home> - 'Wayne's Mini Progress'

For updates, stick a 'Like' on Wayne's Mini Progress facebook page.

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