Manual Gearbox - 3 Synchro Internal Components
Manual Gearbox - 3 Synchro Internal Components
Manual Gearbox - 3 Synchro Internal Components
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<strong>Manual</strong> <strong>Gearbox</strong> - Flywheel Housing and Clutch Cover<br />
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks<br />
Flywheel Housing<br />
1 22G999 FLYWHEEL HOUSING , no breather hole 1 1959-68, 3 synchro gearbox, all models .<br />
DAM3165 FLYWHEEL HOUSING , no breather hole 1 1968-69, 4 synchro gearbox, all models.<br />
1969-79, 4 synchro gearbox, not<br />
1275cc .<br />
DAM6259 FLYWHEEL HOUSING , no breather hole 1 1979-92, 4 synchro gearbox, not<br />
1275cc .<br />
2 DAM3161 FLYWHEEL HOUSING , with breather hole 1 1969-79, 4 synchro gearbox, 1275cc.<br />
DAM6257 FLYWHEEL HOUSING , with breather hole 1 1979-91, 4 synchro gearbox, 1275cc<br />
carburetter.<br />
TRD10015 FLYWHEEL HOUSING , with breather hole 1 1991 on, 4 synchro gearbox, 1275<br />
and crank sensor hole<br />
injection and carburetter.<br />
3 88G302 BEARING, idler gear (1.004" ext. dia.) 1 1959-68, 3 synchro gearbox.<br />
13H7848 BEARING, idler gear (1 1/16" ext. dia., 1 1968-79, 4 synchro gearbox.<br />
3/4" int. dia.)<br />
AHU1707 BEARING, idler gear (1 3/8" ext. dia., 1 1979 on, 4 synchro gearbox.<br />
7/8" int. dia.)<br />
DAM3745 BEARING, idler gear, special, with sleeve 1 For use, see note below.<br />
(1 3/8" ext. dia., 3/4" int. dia.)<br />
4 LCG10001 BLANKING PLATE, crank sensor hole 1 1992-94, 1275 carburetter.<br />
5 FS105101 SCREW, blanking plate to 2 1992-94, 1275 carburetter.<br />
flywheel housing<br />
Interchangeability of flywheel housings:<br />
For 1959-68 models (3 synchro gearbox), none of the later 4 synchro flywheel housings can be used in<br />
place of the original.<br />
For 1968-79 models (not 1275), flywheel housing DAM6259 may be used, so long as the special idler<br />
bearing with sleeve DAM3745 is also fitted.<br />
For 1968-69 models (1275 only), flywheel housing DAM6259 may be used, so long as the special idler<br />
bearing with sleeve DAM3745 is also fitted.<br />
For 1969-79 models (1275 only), flywheel housing DAM6257 may be used, so long as the special idler<br />
bearing with sleeve DAM3745 is also fitted. Alternatively, flywheel housing TRD10015 may be used, so<br />
long as LCG10001 crank sensor hole blanking plate and two off FS105101 screws are also fitted, along<br />
with the special idler bearing and sleeve DAM3745.<br />
For 1979-91 models (1275 carburetter), flywheel housing TRD10015 may be used, so long as LCG10001<br />
crank sensor hole blanking plate and two off FS105101 screws are also fitted.<br />
These notes show how to use later flywheel housings on earlier 4 synchro power units - they do<br />
rely on the original idler gear being retained. If you’re not sure what’s original on the car for<br />
its year, to be sure you may have to dust off a vernier caliper and deduce (i) the external<br />
diameter of the idler gear bearing required (measure the bearing location in the flywheel housing)<br />
and (ii) the internal diameter required (measure the idler gear shaft diameter). You should then<br />
be able to find a bearing size suiting your purposes from the Somerford Mini range above.<br />
6 13H2934 OIL SEAL, clutch (primary gear oil seal)1 All carburetter models.<br />
LUF10005 OIL SEAL, clutch (primary gear oil seal) 1 All injection models .<br />
7 DAM2821 SHIELD, oil seal protection 1 1982 on; all Verto clutch models.<br />
8 AAU8424 BEARING, first motion shaft 1<br />
9 2A3643 CIRCLIP, bearing to flywheel housing 1<br />
10 CCN110 CIRCLIP, bearing to first motion shaft 1<br />
11 GUG705563GM GASKET, flywheel housing to cylinder 1<br />
block/gearbox<br />
12 18G8086 LOCK TAB KIT, clutch 1 Includes lock tabs for strap and<br />
flywheel securing screws, plus lock<br />
tabs for flywheel housing screws.<br />
13 22A1762 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit.<br />
14 22A1761 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit.<br />
15 2A3521 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit.<br />
16 22A1241 LOCK TAB, flywheel housing attachment 1 1968 on (4 synchro gearbox);<br />
included in clutch lock tab kit.<br />
17 BH605141 BOLT, long, flywheel housing attachment 3<br />
DAM7758 BOLT, flanged, long, flywheel housing 3 Alternative.<br />
attachment<br />
18 LWZ305 WASHER, locking 3<br />
19 SH605081 SCREW, shor t, flywheel housing 3<br />
attachment<br />
DAM7753 BOLT, flanged, shor t, flywheel housing 3 Alternative.<br />
attachment<br />
20 FNZ505 NUT, flywheel housing attachment 9<br />
21 LWZ305 WASHER, locking 4<br />
22 22A1299 PLATE, dowel retaining 1 1968 on (4 synchro gearbox).<br />
For certain markets or on certain models during the 1960s, the starter solenoid was fixed to a bracket<br />
attached to the flywheel housing:<br />
23 12A369 BRACKET, starter solenoid to flywheel 1 Not Cooper S models.<br />
housing<br />
12G326 BRACKET, starter solenoid to flywheel 1 Cooper S models.<br />
housing<br />
24 SH505051 SCREW, bracket to flywheel housing 2<br />
25 LWZ305 WASHER, locking 2<br />
Clutch Cover and Clutch Release Mechanism<br />
1959-82, Coil Spring or Diaphragm Clutch<br />
26 88G300 COVER, clutch,with timing hole 1<br />
27 2A3635 COVER, timing hole 1<br />
28 SH604041 SCREW, timing hole cover to clutch cover 2<br />
29 LWZ304 WASHER, locking 2<br />
30 53K146 SCREW, clutch cover to flywheel housing 8<br />
DAM7755 BOLT, flanged head, clutch cover to 8<br />
flywheel housing<br />
31 LWZ305 WASHER, locking 8<br />
32 22A180 PLUNGER, clutch release 1 Release bearing secures by press-fit.<br />
33 DAM1955 PLUNGER, clutch release 1 Alternative; release bearing secures<br />
with clip.<br />
34 DAM2413 CLIP, release bearing to plunger 1 Use with DAM1955 plunger.<br />
35 22A427 NUT, clutch release stop 1<br />
36 NT610041 NUT, locking clutch release stop nut 1<br />
The very ear liest cars from 1959-60 were originally fitted with a plunger with an integral (nonadjustable)<br />
stop. This may be replaced by either of the plungers listed above, to gether with a 22A427<br />
stop nut and NT610041 lock nut.<br />
37 22A2204 LEVER, clutch release 1<br />
38 CLZ628 CLEVIS PIN, lever pivot in clutch cover 1<br />
39 PWZ106 WASHER, plain 1<br />
40 ZPS307 SPLIT PIN 1<br />
41 SH604091 SCREW, lever adjusting 1<br />
42 FNZ604 NUT, locking adjusting screw 1<br />
43 CLZ518 CLEVIS PIN, lever to slave cylinder 1<br />
push rod<br />
44 PWZ105 WASHER, plain 1<br />
45 ZPS306 SPLIT PIN 1<br />
46 1G5999 SPRING, clutch release lever 1<br />
47 2A3601 ANCHOR, spring, clutch release lever end 1<br />
48 2A3600 ANCHOR, spring, slave cylinder end 1<br />
1982 On, Verto Clutch<br />
49 AHU1068 COVER, clutch,with timing hole 1 1982-85; with inertia star ter.<br />
AHU1106 COVER, clutch,without timing hole 1 1985 on; with pre-engaged starter.<br />
50 2A3635 COVER, timing hole 1 1982-85.<br />
51 SH604041 SCREW, timing hole cover to clutch cover 2 1982-85.<br />
52 LWZ304 WASHER, locking 2 1982-85.<br />
53 53K146 SCREW, clutch cover to flywheel housing 7<br />
DAM7755 BOLT, flanged head, clutch cover to 7<br />
flywheel housing<br />
54 LWZ305 WASHER, locking 7<br />
The eighth screw used to secure a Verto clutch cover is the long screw securing the slave cylinder bracket<br />
(please see Clutch Pedal and Hydraulics section).<br />
55 DAM5353 PLUNGER, clutch release 1<br />
56 AAU2866 O RING, release bearing 1<br />
57 22A427 NUT, clutch release stop 1<br />
58 NT610041 NUT, locking clutch release stop nut 1<br />
59 DAM5355 LEVER, clutch release 1<br />
60 CLZ628 CLEVIS PIN, lever pivot in clutch cover 1<br />
61 PWZ106 WASHER, plain 1<br />
62 ZPS307 SPLIT PIN 1<br />
63 SH604091 SCREW, lever adjusting 1<br />
64 FNZ604 NUT, locking adjusting screw 1<br />
65 CLZ518 CLEVIS PIN, lever to slave cylinder 1<br />
push rod<br />
66 PWZ105 WASHER, plain 1<br />
67 ZPS306 SPLIT PIN 1<br />
Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk<br />
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