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#Post#: 89445--------------------------------------------------
Sam's Gearbox Overhaul
By: samc88 Date: June 13, 2014, 4:31 pm
---------------------------------------------------------
Right then, as you may know, my series 3 has problems with 2nd
gear. I picked up a new (second hand) gearbox from selwyn at the
excellent Bryn Glas Garage in Bryngwran. Picked it up from under
some brambles and theres a plate on the bellhousing which shows
it to be a factory recon unit (hard to make it out but it reads
" The Rover Co. Ltd, Factory Rebuild" )
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130013.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130014.jpg.html][IMG]http://…
This is the only serial number I've found on it, on the side of
the main case, "5766588A", does this make it a suffix A box?
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130015.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130016.jpg.html][IMG]http://…
First task is to remove the gearlever.
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130018.jpg.html][IMG]http://…
This I did by first removing the 2 larger bolts at the rear
using a 15mm spanner (the gearbox I know should be whitworth but
found a 15mm spanner to fit perfectly)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130017.jpg.html][IMG]http://…
I then removed the shorter bolt at the front using an 11mm
spanner. (there should be 2 bolts but only one was present)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130021.jpg.html][IMG]http://…
The bolts holding the main gear lever in place
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130022.jpg.html][IMG]http://…
The 2 smaller bolts also hold down this plate in the bellhousing
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130023.jpg.html][IMG]http://…
As soon as it is removed, I like to put the bolts back where
they came from to avoid losing them and so I dont get confused
as to what goes where
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130024.jpg.html][IMG]http://…
The whole gear lever assembly can be pulled off
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130026.jpg.html][IMG]http://…
The selectors
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130028.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130029.jpg.html][IMG]http://…
Next job is to remove the Bell housing, before this can be done
however, the clutch fork needs to be removed. The book gives it
like this
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130031.jpg.html][IMG]http://…
The bearing was not present on mine and the fork simply popped
off the ball joint (I think the clip is worn)
The ball joint
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130032.jpg.html][IMG]http://…
The fork
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130033.jpg.html][IMG]http://…
Next up is removal of the bell housing itself
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130030.jpg.html][IMG]http://…
First is to remove the oil seal housing in the bell housing
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130034.jpg.html][IMG]http://…
The 4 upper nuts where removed using a 1/4" Whitworth socket
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130035.jpg.html][IMG]http://…
The 2 lower bolts and 1 nut were removed using a 7/16" socket
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130037.jpg.html][IMG]http://…
I had to knock the assembly with a mallet to get it free enough
to pull off
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130039.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130040.jpg.html][IMG]http://…
There is some play in the upper bearing so that will be replaced
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130041.jpg.html][IMG]http://…
The layshaft retaining bolt is next to be removed
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130042.jpg.html][IMG]http://…
I used a socket on this and by holding the mainshaft by hand I
was able to undo the bolt (it wasn't particularly tight)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130045.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130046.jpg.html][IMG]http://…
The 4 fixings which connect the bell housing to the main gearbox
casing are next to be removed. I used a 7/8" spanner and socket
on a breaker bar to get these out. (as you can see the earlier
oil seal housing bolts have been put back in place so I don't
lose them)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130047.jpg.html][IMG]http://…
The bellhousing was then tapped with a mallet and it started
coming apart
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130048.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130049.jpg.html][IMG]http://…
When the bellhousing comes off it brings the layshaft constant
gear and conical distance piece with it
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130050.jpg.html][IMG]http://…
This is how they should look on the layshaft
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130051.jpg.html][IMG]http://…
Bellhousing
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130052.jpg.html][IMG]http://…
The layshaft was then pulled out
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130053.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130054.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130058.jpg.html][IMG]http://…
A view inside the main casing
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130056.jpg.html][IMG]http://…
Reverse gear
[URL=
http://s1126.photobucket.com/user/110samec/media/P6130057.jpg.html][IMG]http://…
Tomorrows job is to look at the selectors and fetch the
mainshaft out to have a look at it
#Post#: 89451--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Arjan Date: June 14, 2014, 2:57 am
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:thumbs: :thumbs: :thumbs:
Keep it coming - very informative
#Post#: 89483--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: June 14, 2014, 6:03 pm
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Right then, onto the selectors.
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140063.jpg.html][IMG]http://…
First I removed the reverse and 1st gear detent springs using
an 11mm spanner
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140002.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140003.jpg.html][IMG]http://…
There is a seal between the spring and the bracket
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140004.jpg.html][IMG]http://…
Next was the top detent spring for 3rd gear, which cmae off
using a 5/16" Whitworth spanner
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140009.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140010.jpg.html][IMG]http://…
Before removing the top cover, I had to remove the overdrive
bracket which had been fitted to this gearbox. The nuts and
bolts came off with a 1/4" whitworth spanner and socket
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140006.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140006.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140008.jpg.html][IMG]http://…
The 2 nuts also need to come off using a 5/16" whitworth socket/
spanner
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140012.jpg.html][IMG]http://…
The stud came with the nut
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140013.jpg.html][IMG]http://…
The cover can then be lifted off revealing the selector shafts.
Be careful not to lose the 3 ball bearings that were under the
detent springs
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140014.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140015.jpg.html][IMG]http://…
The detent spring assembly
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140016.jpg.html][IMG]http://…
There are 2 small rollers on top of the main casing, be careful
not to lose these
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140018.jpg.html][IMG]http://…
Select third gear and the selector shafts can then be lifted
out. Its a bit fiddly to do this with the shafts in place but
they do come out. First out is the reverse shaft
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140019.jpg.html][IMG]http://…
Then the 3rd/4th shaft
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140020.jpg.html][IMG]http://…
This has a small pin along the shaft, be careful it doesnt drop
out or you'll never find it again
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140021.jpg.html][IMG]http://…
First selector
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140022.jpg.html][IMG]http://…
Revealing the mainshaft
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140023.jpg.html][IMG]http://…
The bearing slides off the mainshaft
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140025.jpg.html][IMG]http://…
As does the 3rd/ 4th synchro hub
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140026.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140027.jpg.html][IMG]http://…
Mine doesnt look bad at all aoart from its missing a leaf spring
(which I found in the bottom of the box)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140027.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140028.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140030.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140032.jpg.html][IMG]http://…
Before drifting the mainshaft out, I decided to take the
transfer box out to make everything a more manageable size
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140065.jpg.html][IMG]http://…
Before starting this the brake back plate needs removing. Take
out the split pin in the castle nut and undo the nut (I had to
use an impact gun on this as it was tight and due to lack of
rear mainshaft gear I cant put in gear)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140033.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140034.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140035.jpg.html][IMG]http://…
The rear output flange then just slides off
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140036.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140037.jpg.html][IMG]http://…
These 4 nuts holding the back plate to the speedo housing are
next to be removed, again with a 5/16" whitworth spanner
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140038.jpg.html][IMG]http://…
Once thats off, take off the retaining nut and bracket for the
intermediate shaft, again 5/16" whitworth
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140040.jpg.html][IMG]http://…
Using a pry bar, you can withdraw the shaft
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140041.jpg.html][IMG]http://…
Before taking it out fully, take off the bottom plate (check
theres no oil in it first though, I forgot so ended up with a
workbench covered in old EP90 :o )
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140042.jpg.html][IMG]http://…
The shaft can now be withdrawn whilst you support the
intermediate gear cluster
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140043.jpg.html][IMG]http://…
The cluster can now be rolled out the box
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140044.jpg.html][IMG]http://…
Revealing the thrust washers either side
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140045.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140047.jpg.html][IMG]http://…
They're a bit worn so will get new ones
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140048.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140049.jpg.html][IMG]http://…
Gears look good
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140050.jpg.html][IMG]http://…
With that out of the way, the fastenings holding the gearbox to
the transfer box can be removed (using you guessed it, a 5/16"
whitworth socket)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140052.jpg.html][IMG]http://…
Next the external fastenings were removed
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140053.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140054.jpg.html][IMG]http://…
Allowing the boxes to be split
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140055.jpg.html][IMG]http://…
With the transfer box out of the way, it was now time to remove
the mainshaft.
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140065.jpg.html][IMG]http://…
First task is to remove the mahoosive circlip holding the
housing in place
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140056.jpg.html][IMG]http://…
Then the mainshaft can be drifted downwards and out of the box
(support the casing on bits of wood to give the shaft more room
to come out the box)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140057.jpg.html][IMG]http://…
Little bit of surface rust on one or 2 components but not bad
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140058.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140059.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140060.jpg.html][IMG]http://…
No chips on the teeth at all which is something
Next up is splitting the transfer box and front output shaft
housing
First remove the cover plate using a 1/2" spanner
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140066.jpg.html][IMG]http://…
Then remove the Detent spring using a 5/16" whitworth
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140068.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140071.jpg.html][IMG]http://…
Remove the transfer selector fork pinch bolt using a 1/4"
whitworth spanner
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140073.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140074.jpg.html][IMG]http://…
Next remove the fixings holding the housing to the transfer main
case
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140075.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140076.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140077.jpg.html][IMG]http://…
Once the output housing is free, remove the 4 wheel drive
selector
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140078.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140079.jpg.html][IMG]http://…
The dust cover can now be removed using a 3/16" whitworth
spanner
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140080.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140081.jpg.html][IMG]http://…
The shafts can then be drifted out gently
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140082.jpg.html][IMG]http://…
Next remove the front output flange, which is exactly the same
process as the rear one
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140083.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140084.jpg.html][IMG]http://…
Revealing the oil seal housing
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140085.jpg.html][IMG]http://…
Which can be pulled off once the nuts are removed
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140087.jpg.html][IMG]http://…
The output shaft can now be withdrawn
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140088.jpg.html][IMG]http://…
The bearing can now be drifted out. I used a 32mm socket on the
end of a long extension bar as a drift for getting it out
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140091.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140092.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140093.jpg.html][IMG]http://…
Now, as I have another spare output housing which was clean I
decided to use that one
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140094.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140095.jpg.html][IMG]http://…
I decided to rebuild the output housing as I have all the bits
required to do it
The bearing was greased and pressed in the housing using the
trusty old fly press
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140097.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140098.jpg.html][IMG]http://…
A gasket was then made for the oil seal housing (using the old
one as a pattern)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140103.jpg.html][IMG]http://…
The old oil seal was then prised out (put the housing pointing
down in the vice, flanges resting on the jaws and punched the
seal out)
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140104.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140105.jpg.html][IMG]http://…
The new seal
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140106.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140108.jpg.html][IMG]http://…
Smear the outside of the seal with hylomar blue
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140107.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140109.jpg.html][IMG]http://…
Press the seal in place, I like to put a smear of grease on the
lip to lubricate whatever gets pushed through it.
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140110.jpg.html][IMG]http://…
The housing can then be bolted back on with the gasket and a
smear of hylomar either side
The front output shaft can be then put in place again. The
flange can then be slid on, this is a spare one I have, the mud
shield on the other one was a bit mis-shapen
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140111.jpg.html][IMG]http://…
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140112.jpg.html][IMG]http://…
Washer in place
[URL=
http://s1126.photobucket.com/user/110samec/media/P6140113.jpg.html][IMG]http://…
The nut is then put in place and torqued up to 85 lb/ ft
Tomorrows job is selector shafts and strip down the transfer box
I think
#Post#: 89484--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: mandylandy Date: June 15, 2014, 1:55 am
---------------------------------------------------------
Nothing short of BRILLIANT.
I have a spare box that I dare not touch,maybe I will find the
balls one day!
Thanks x. :lightblb: :smilewide:
#Post#: 89497--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: puddlejumper Date: June 15, 2014, 4:38 am
---------------------------------------------------------
:thumbs: :thumbs: :thumbs:
Fantastic thread, very useful.......well done
#Post#: 89502--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Serious Series Date: June 15, 2014, 9:42 am
---------------------------------------------------------
When replacing transfer case intermediate gear as well as
replacing brass faced washers worth getting some of part No
561197 which are a packing shim so that you can get the correct
end float on the shaft they are rarely fitted but if two much
end float then going on and off load gear train moves on shaft
and is cause of some of the gearing noise.
Where the gear teeth are rusted the gear will have lost its
hardened surface so life of gear will be shortened .
You can soak them in vinegar to remove full depth of rust to see
how bad they are.
Looks like a suffix A box as stated earlier.
#Post#: 89505--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Albert Ross Date: June 15, 2014, 10:39 am
---------------------------------------------------------
Look closely at the pictures of the 3/4 synchro hub. There is a
milling on the inner sleeve, and this faces the rear, as it fits
over the retainer for the mainshaft cluster. Get it wrong, and
you'll never stay in 3rd....
#Post#: 89507--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: June 15, 2014, 11:12 am
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Thanks for the advice guys! Albert Ross, thanks for that, I
never noticed the difference between the ends, have marked it
though.
It is a suffix A, the reverse gear is on a bush which has a
little bit of wear in it so I will replace it whilst Im at this
stage. Looking at the gears and after some advice recieved
elsewhere, 1st, 2nd, 3rd and the layshaft will be replaced. the
dog teeth on the 1st and 2nd gear are chipped and 3rd is rusty
#Post#: 89508--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: harryhedgehog Date: June 15, 2014, 11:23 am
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Liking this, keep up the good work :thumbs:
HHH
#Post#: 89526--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: StuartN Date: June 16, 2014, 2:25 am
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Very comprehensive, thank you.
Sticky??
S
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