21 replies to this topic

[aguiloco]

Hello, I got the necessary bolts to extract the flywheel, I maxed the pressure of my hydraulic puller, and with a small tab it flew out of the crank.

 

 

Even with the new seal, it leaked some oil.

 

 

 

 

I inspected the gearbox, I didn't find any obviously broken parts, just some small silicone bits from the sealing. I can't feel excessive slop at the bearings. Here are some videos i took, maybe you can see something I can't.

 

https://youtu.be/MLUtKQfmvz4

 

https://youtu.be/Z1xNQe3sA0c

 

Here is the differential, It seems to move freely and smoothly. Is that too much play?

 

https://youtu.be/tJ1gCU3mzMw

 

I can't find my feeler gauges, so I have to measure endfloats...

 

These are the parts I found broken. First, the primary gear, internal collar, looks pretty worn, I measured the slop at the crankshaft in the video.

 

 

 

https://youtu.be/FwTnmteGAbg

 

Last, the idle gear, I can't detect any vertical slop in the bearings, but the endfloat looks way off. I need those gauges...

 

https://youtube.com/...E?feature=share

 

I think the sleeves on the primary gear can be replaced. I imagine it is a delicate task, and I'll need a good machinist.

 

Idle gear thrust washers could be replaced to adjust endfloat, right?

 

I have to check CVs too.

 

Any thoughts or pointers so far?

 

Thank you very much.

[Spider]

From what I could see in your clips, your gearbox may need a new selector fork for 1st / 2nd gear, not uncommon. Now doubt, when stripped, there'll be other other items too.

The Primary Gear bushes are most definitely karput. There are a few NOS ones still available, if you can find one and it fits up in spec, that would likely work out cheaper than replacing the bushes and it'll have the right bushes in it. I don't like the current offerings of replacement bushes, they eat crankshafts.

I think you found your 'klack' with the end float of the Idler Gear, the end float there is huge.

[Spider]

Oh and the diff needs a full overhaul too, including bushes.

[aguiloco]

Considering untrustworthy bushes and my lack of trust in someone else's work, buying a new OEM primary gear seems reasonable. How much is that?

 

When the car was driving, I didn't notice anything wrong going from 1st to 2nd, but indeed, that fork seems to be a bit worn. I'll measure the gap.

 

So far, I have found only worn parts, nothing that could explain a sudden change in rattling after a high-load situation, and that's what's getting me.

 

Do you suggest a complete overhaul of the gearbox? Synchos feel all right; the conical parts that act like a simple clutch between gears still have plenty of life, I don't know what they are called...

 

Bearings feel OK. I could replace them, but I'm not sure it's necessary. Maybe I should disassemble it completely to check them.

 

I'm trying to fix this the cheapest way possible, I'm buying a new home with a proper garage, lots of expenses these days.

 

Thanks Spider!

[Spider]

To replace the Selector Fork you pretty much need to strip the gearbox to the last nut, so while it's in bits, give it a birthday, save you coming back to it in a year or so.

[Ethel]

That crane's bigger than the car! Still it'll come in handy for lifting that flywheel puller 

[aguiloco]

Replacing all bearings, seals, shims, gaskets and a new primary gear is going to get expensive, I'll have to wait a bit until I sort out my mortgage situation.

Indeed it is a big crane! In theory I could lift 2 complete Minis, but being cheap I take the ratings and divided by half just to be sure, had to replace a couple of dubious screws.