mark powell Posted October 18, 2023 Report Share Posted October 18, 2023 Following the loss of 2nd and 3rd gears on my trip up to North Wales from Sussex, earlier in the year, I have finally found time to pull the 'box and investigate. Pictures speak louder than words. Hopefully my box of a previously dismantled gearbox will supply the parts needed. Oh, and the output shaft main bearing had disintegrated as well... Link to comment Share on other sites More sharing options...
Pete Lewis Posted October 18, 2023 Report Share Posted October 18, 2023 ouch !!!! Pete Link to comment Share on other sites More sharing options...
mark powell Posted October 18, 2023 Author Report Share Posted October 18, 2023 Yep! I will endeavour to rebuild, but it will be a bit of a learning curve, as I haven't done one before. Still, original w/s manual should help... Link to comment Share on other sites More sharing options...
johny Posted October 18, 2023 Report Share Posted October 18, 2023 Oh dear this is worrying! How much noise did it make before failing, a gradual build up or sudden? Obviously had plenty of oil I hope? Unusual for main brg to go and what were the three needle roller bearings like? Was the input shaft support bush in the crank very loose? Im asking as I worry about whats going on in my original 80k vitesse box😱 Link to comment Share on other sites More sharing options...
Pete Lewis Posted October 18, 2023 Report Share Posted October 18, 2023 all you need is a soft drift and hammer but you have it in bits already tip when refitting the D type use two big screwdrivers or similar and when lowering the unit lever open the steel strap bars to free the clutch this allows everything to align and the unit will drop on easy keep fingers out the way !!!!! the manual will tell you to use a long screwdriver and poke around in the dark to get the splines lined up ...all pretty hopeless the gag to lever open is twit proof or you will be poking around for hours pete Link to comment Share on other sites More sharing options...
dougbgt6 Posted October 18, 2023 Report Share Posted October 18, 2023 I'm always amazed at how badly damaged they can be and still, sort off, work. I rebuilt a mini gearbox following the workshop manual, how difficult could it be? How naïve was I? But it ran another 5 years. With the wisdom of age and experience I wouldn't even consider it now, I'd send it away to a gearbox magician. Doug Link to comment Share on other sites More sharing options...
Nigel Clark Posted October 18, 2023 Report Share Posted October 18, 2023 That looks nasty! If you decide have a professional rebuild of the gearbox, I can recommend someone in North Wales.... My brother, who has over 30 years experience, including Triumph 'boxes. Nigel Link to comment Share on other sites More sharing options...
mark powell Posted October 18, 2023 Author Report Share Posted October 18, 2023 7 minutes ago, Nigel Clark said: That looks nasty! If you decide have a professional rebuild of the gearbox, I can recommend someone in North Wales.... My brother, who has over 30 years experience, including Triumph 'boxes. Nigel I could be very tempted, have you got his contact details? Link to comment Share on other sites More sharing options...
johny Posted October 18, 2023 Report Share Posted October 18, 2023 Who ever does it needs a good stock of spares, new in a dream world or second hand more likely... Link to comment Share on other sites More sharing options...
Nigel Clark Posted October 18, 2023 Report Share Posted October 18, 2023 47 minutes ago, mark powell said: I could be very tempted, have you got his contact details? PM sent Link to comment Share on other sites More sharing options...
mark powell Posted October 18, 2023 Author Report Share Posted October 18, 2023 Further investigation results in a difference between my spare layshaft cluster and the damaged one. Different teeth, so not a straight swap. The spare ones look well worn. Now tempted to locate a used standard non-overdrive box... I still have standard prop shafts, so that's not a problem. Link to comment Share on other sites More sharing options...
johny Posted October 18, 2023 Report Share Posted October 18, 2023 Yes as well as different ratios the gear tooth angle and synchro ring size and number changed over the life of that gearbox design. You have a higher chance of finding a good used non OD unit but of course theres no guarantees or real way of knowing its internal condition☹️ Link to comment Share on other sites More sharing options...
mark powell Posted October 18, 2023 Author Report Share Posted October 18, 2023 True, but at least I should be able to get mobile. Link to comment Share on other sites More sharing options...
johny Posted October 18, 2023 Report Share Posted October 18, 2023 Dont forget youll need a different mounting plate and rubber mounts for a non OD box however I think your speedo cable although longer will still do the job... Link to comment Share on other sites More sharing options...
Pete Lewis Posted October 18, 2023 Report Share Posted October 18, 2023 so why if you use a non OD slave dont you just swap the mainshafts over ??? and you still have the benefit of overdrive with the changes in tooth count and tooth angles it can become a minefield of lots of spares............ fits nothing Pete Link to comment Share on other sites More sharing options...
johny Posted October 18, 2023 Report Share Posted October 18, 2023 That looks like the 4th gear synchro and tip needle roller bits in the photo so cant imagine the mainshaft is very healthy☹️ Link to comment Share on other sites More sharing options...
mark powell Posted October 18, 2023 Author Report Share Posted October 18, 2023 1 hour ago, johny said: Dont forget youll need a different mounting plate and rubber mounts for a non OD box however I think your speedo cable although longer will still do the job... I've got all the necessary fittings, retained from when I changed to o/d.. 1 Link to comment Share on other sites More sharing options...
mark powell Posted October 20, 2023 Author Report Share Posted October 20, 2023 I'm going for a used late full synchro box. I'm not anticipating any long trips, so won't miss o/d. Anyway, I have a higher ratio diff, so no real problem. I will have the D type o/d available for sale, I think the mainshaft is ok. Obviously it will come with all fittings. Link to comment Share on other sites More sharing options...
mark powell Posted October 20, 2023 Author Report Share Posted October 20, 2023 Another question? At the bottom of the gearlever, under the nylon ball, some manuals show a 'washer' part no.13. There is a recess in the lever and I found a rubber 'o' ring on one of my spare levers in this recess. Should this be correct, or should there be another steel washer as I found on another of my spare levers? Link to comment Share on other sites More sharing options...
mark powell Posted October 20, 2023 Author Report Share Posted October 20, 2023 Part no13 is shown on the original w/s manual, not on the current suppliers diagrams... which don't show a washer under the nylon ball at all. Link to comment Share on other sites More sharing options...
mark powell Posted November 26, 2023 Author Report Share Posted November 26, 2023 Replacement gearbox installed with standard length propshaft (with later, larger, flanges and new u/j's), First test drive today, all good. Great to be mobile again! Link to comment Share on other sites More sharing options...
johny Posted November 26, 2023 Report Share Posted November 26, 2023 Excellent. The non OD boxes have a reputation for being longer lasting than the OD version so if you can get by without all good.... Link to comment Share on other sites More sharing options...
mark powell Posted November 26, 2023 Author Report Share Posted November 26, 2023 Always a risk fitting a used box, seller removed it to fit o/d and was sure it was good. So far, so good! Seems to be worth the 7 hour round trip to collect it! Link to comment Share on other sites More sharing options...
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