Manual Gearbox - 3 Synchro Internal Components

Manual Gearbox - External Components
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks
Rebuilt or Repaired Gearbox Assemblies
Somerford Mini Ltd. offers a gearbox rebuilding and repair service through its workshop facility. We can
carry out repairs or rebuilds on late-model gearboxes, but can only realistically offer a repair service for
the earlier designs because of, frankly, poor overall par ts availability in the marketplace. Please
contact us to discuss your Mini gearbox requirements - it would be helpful if you could supply us not
only the details of what’s gone wrong with your gearbox, but the age (if known) and type (3 or 4
synchro, A or A Plus, gearchange type and driveshaft type). The more you can provide us with, the
better we can ascertain how we might possibly help you.
It has to be said that at time of writing, spares availability for 1959-68 3 synchromesh gearboxes is not
very good at all and unfortunately because of the high cost involved in reintroducing some components,
the situation is unlikely to get much better in the forseeable future. Rest assured, however, that we will
always do whatever we can to help you. The later 4 synchromesh gearboxes fare much better, especially
of course the rod change variety which were in production between 1973 and 2000. Having said that,
there are some surprising gaps in parts availability, even for 1980s rod change gearboxes.
The general rule is that the older the gearbox type, the more components are not available new and
the less likely a totally comprehensive rebuild will be possible.
5 Speed Gearbox Assemblies
5 speed rod-change gearboxes have generated much interest for some years now, with several
organisations producing their own designs (Jack Knight Developments, KAD and Mini Spares, for example).
Please contact us to establish which are currently available.
Differential Cover Attachment
1 2A3505B GASKET, cover to gearbox case, upper 1
2 2A3506B GASKET, cover to gearbox case, lower 1 1959-73 Saloon and Estate; 1960-75
Van and Pick Up. Direct or remote
gearchange.
3 22G1836B GASKET, cover to gearbox case, lower 1 1973 on Saloon; 1973-82 Estate;
1976-84 Van and Pick Up. Rod
gearchange.
4 BHYL001 HYLOMAR SEALANT, 100g tube A/R Use with gaskets.
5 22A153 DOWEL,cover to gearbox case 2
6 22G1834 STUD, cover to gearbox case, long 4/2 Qty. reduces for rod gearchange.
7 FNZ506 NUT 4
8 CHS522 STUD, cover to gearbox case, shor t 3
9 DAM7760 BOLT, flanged, cover to gearbox case , shor t 3 Alternative to stud from 1985 on.
10 FNZ505 NUT 3
11 LWZ305 WASHER, locking 3
12 22A74 LOCK TAB, cover to gearbox case, large 2 1959-62 direct gearchange.
22A74 LOCK TAB, cover to gearbox case, large 1 Direct or remote gearchange.
13 42H500 LOCK TAB, cover to gearbox case, large 1 Rod gearchange .
14 22A251 LOCK TAB, cover to gearbox case, small 1 1962 on.
15 22A252 LOCK TAB, cover to gearbox case, small 1 1962-71 appro x.
The 22A251 and 22A252 small lock tabs replaced one of the 22A74 large lock tabs in 1962. 22A252
was quietly dropped in the early 1970s and is no longer considered necessary to fit.
Flywheel Housing Attachment
16 GUG705563GM GASKET, housing to cylinder block/gearbox 1
17 22A97 DOWEL, housing to gear case 2
18 22A152 STUD, housing to gear case, long 6
19 DAM7759 BOLT, flanged, housing to gear case, long 6 Alternative to stud, 1985 on.
20 53K547 STUD, housing to gear case, short 3
21 DAM7756 BOLT, flanged, housing to gear case, short 3 Alt. to stud, 1985 on, not 1275cc.
DAM7756 BOLT, flanged, housing to gear case, short 1 Alt. to stud, 1985 on; 1275cc.
DAM7757 BOLT, flanged, housing to gear case, short 2 Alt. to stud, 1985 on; 1275cc.
For nuts, washers and lock tabs for the above studs, plus hardware used to attach the flywheel
housing to the cylinder block, please see the ‘Flywheel Housing and Clutch Cover’ section.
Speedometer Pinion Housing Attachment
22 DAM5219 HOUSING, speedometer pinion 1
23 GUG705569GM GASKET, housing to gearbox case 1
24 22A13 DOWEL,housing to gearbox case 2
25 SH505091 SCREW, coarse thread, housing to gearbox 5
case
26 LWZ305 WASHER, locking 5
27 53K1474 STUD, housing to gearbox case 3
28 DAM7761 BOLT, flanged, housing to gearbox case 3 Alternative to stud from 1985 on.
29 53K551 STUD, engine mounting to housing 1 Not 850 models, 1959-68.
53K545 STUD, engine mounting to housing 1 850 models , 1959-68.
30 FNZ505 NUT 4
31 LWZ305 WASHER, locking 4
32 2A3626 END PLATE, housing 1
33 GUG705564GM GASKET, end plate to housing 1
34 SH504061 SCREW, coarse , end plate to housing 2
35 LWZ304 WASHER, locking 2
Cylinder Block Attachment
36 GUG106SS GASKET SET, gearbox case to cylinder block 1
37 AHU1959 SEAL, oil, front main bearing cap 1 ‘Half Moon’ seal.
38 22H983 DOWEL,gearbox case to cylinder block 1
39 FHS2410 STUD, gear case to thick flanged block 2 Not Cooper or Cooper S, 1961-67.
FHS2409 STUD, gear case to thin flanged block 2 Cooper and Cooper S, 1961-67.
40 FNZ504 NUT 2
41 LWZ304 WASHER, locking 2
42 SH604081 SCREW, gearbox case rear to cylinder block 5
43 BH604121 BOLT,gearbox case front to cylinder block 5
44 LWZ304 WASHER, locking 10
45 BH604121 BOLT, dowel 1
46 12A1150 COLLAR, dowel bolt 1
47 PWZ104 WASHER, plain 1
48 FNZ104 NUT 1
Gearbox Case Fittings
49 GEG804 GASKET SET, gearbox 1 Includes all gaskets, oil seals and sealing
washers; direct and remote gearchange.
GUG708002TS GASKET SET, gearbox 1 Includes all gaskets, oil seals and sealing
washers; rod gearchange to 1996.
GUG708014TS GASKET SET, gearbox 1 Includes all gaskets, oil seals and sealing
washers; rod gearchange 1997 on.
50 18G8085 LOCK TAB KIT, gearbox 1 Includes lock tabs for the differential
cover and oil strainer, for direct,
remote or rod change gearboxes.
51 2A3502 BUSH, gearchange control shaft 2 1959-73 Saloon; 1960-73 Estate;
1960-75 Van and Pick Up. Direct and
remote gearchange .
52 13H7286 BUSH, ‘Metalastic’, gearchange steady rod 1 1973 on Saloon; 1973-82 Estate;
1976-84 Van and Pick Up. Rod change.
53 AHU1672 OIL SEAL,selector shaft, in differential cover1 1973 on Saloon; 1973-82 Estate;
1976-84 Van and Pick Up. Rod change.
54 DAM7764 BUSH, selector shaft 1 Rod gearchange up to 1985 approx.
Replace with SSK001 selector oil seal kit.
55 DAM8706 BUSH, aluminium, selector shaft, improved 1 Rod gearchange 1985 approx. on.
56 CDU1563 O RING, selector shaft 1 Rod gearchange 1985 approx. on.
57 DAM3022 GAITER, selector shaft 1 1973 on Saloon; 1973-82 Estate;
1976-84 Van and Pick Up. Rod change.
Selector shaft oil seal failure was always a problem on rod gearchange Minis (as any late-model Mini
owner with oil drips on their garage floor will know). The most common remedy effected by owners in
the past was to put two oil seals one behind the other on the selector shaft (there’s just enough space
to do so),the outer one of the two acting both as a secondary seal and also as a secondary shield
behind the gaiter,protecting the inner seal from under-body muck and grit. Most importantly, the
second seal helped to support the selector shaft and hold it in alignment in the gearbox casing.
Factory engineers finally came up with a remedy in 1985,fitting a modified selector shaft bush with a
new O ring to improve the selector shaft alignment. Somerford Mini of course supply all these
parts separately, but we’ve also put them together as an easy-to-buy, easy-to-fit kit for the owner
to modify a pre-1985 Mini or repair a later model.
58 SSK001 SELECTOR OIL SEAL KIT 1 Includes oil seal, gaiter and improved
bush and O ring.
59 88G302 BEARING, idler gear (1.004" ext. dia.) 1 1959-68, 3 synchro gearbox.
13H7848 BEARING, idler gear (1 1/16" ext. dia., 1 1968-79, 4 synchro gearbox.
3/4" int. dia.)
AHU1707 BEARING, idler gear (1 3/8" ext. dia., 1 1979 on, 4 synchro gearbox.
7/8" int. dia.)
DAM3745 BEARING, idler gear, special, with sleeve 1 For use, see note below.
(1 3/8" ext. dia., 3/4" int. dia.)
60 CCN216 CIRCLIP, bearing retaining 1 Use with 88G302 bearing and original
3 synchro 22A304 idler gear.
22G1141 CIRCLIP, bearing retaining 1 Use with 88G302 bearing and original
3 synchro 22A304 idler gear or
replacement 22G943 idler gear.
51K3565 CIRCLIP, bearing retaining 1 Use with 13H7848 bearing.
The DAM3745 bearing with sleeve was intended to allo w a post-1979 service gearbox to be fitted to a
1973-79 car, retaining the original idler and first motion shaft drive gears in that car. Nowadays it
makes a useful conversion par t for those wanting to mix and match their gearbox, idler and drive gears.
61 2A3504 PIVOT PIN, reverse operating lever 1 Direct or remote gearchange.
62 DAM7335 PLUG, drain, magnetic 1
DP1 PLUG, drain, magnetic, extended 1 Use with centre oil pick up pipe.
63 AED172 WASHER, sealing, drain plug 1
64 22A335 STRAINER, oil 1
65 22A341 O RING, pick up pipe 1
66 22A342 BRACKET, strainer 1
67 SH604031 SCREW, strainer to bracket 2
68 22A388 LOCK TAB, strainer to bracket 1 Included in 18G8085 lock tab kit.
69 SH604081 SCREW, bracket to gearbox case 2
70 22A1365 LOCK TAB, bracket to gearbox case 1 Included in 18G8085 lock tab kit.
71 22G1150 PIPE, oil pick up 1 Not 850 models.
22A337 PIPE, oil pick up 1 850 models.
72 C-AHT54 PIPE, oil pick up, centre 1 For fast road or competition use; we
advise the use of DP1 extended drain
plug with this pipe .
73 2A3637 FLANGE, pick up pipe, outer 1
74 22A542B GASKET, pick up pipe flanges 2
75 BH604131 BOLT,pick up pipe flanges to gearbox case 2
76 2K4874 LOCK TAB, flanges to gearbox case 1 Included in 18G8085 lock tab kit.
77 2A3606 O RING, gearbox case to cylinder block 1
Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk
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