JB's Mini Project

[jb]

Got most of the bits n bobs now. Put together the laygears from the new box and the lay shaft from the old box. Putting it alltogether. There's a locking/locating plate on the end of the shafts that's being a pain in the arse though. Will have another crack at it tomorrow and once that's done put the diff off the old box in the new one and start getting it built back up.

[jb]

Need yet more gaskets. So work has stopped for a little bit.

[jb]

Pancake filters for the twin carbs arrived today, hopefully gaskets tomorrow and we can get a bit further getting this engine back in.

[Custard]

Good work Buddy Cant wait to see the finish

[jb]

engine in

was a pain

still lots to do though

cross your fingers that the box works now!

[jb]

Twin carbs can't go on yet. The manifold they came on doesn't fit over the Maniflow exhaust manifold.

[jb]

Turns out that box doesn't work.

Looks like the mini will be off the road for awhile yet.

[ljonez]

Dec 2, 2010 1:46:57 GMT 1 jb said:

Turns out that box doesn't work.

Looks like the mini will be off the road for awhile yet.

What's up with it ?

[jb]

Not sure - but the noises it was making when tested were pretty horrendous.

edit - Dad think it's possibly trying to select two gears, so we might have a look to see if we can solve that.

[ljonez]

Did you remember to change the drop gears? Can't remember which way around it is 1275 on 998 box or 998 on 1275 box but you have to swap the drop gears to match the box

[jb]

It's a 998 on a 1275 box with the 998 diff. Drop gears as in the transfer gears? Primary, idler and first motion? if so what exactly do you have to swap?

[ljonez]

Yep the transfer gears, pretty sure when its a 1275 on a 998 box you have to change the primary and idle for 998 ones, will have a look on the net if it the same when in your situation

[jb]

From what we can gather with the box we have used (1275 from '97-'00) on our engine (998 '89) the idler gear is the same between both so doesn't factor into the swap. Have to use the primary from the 998 because the 1275 is wrong - which we have done.

If we had used a pre A+ or 3-sycnrho then the idler would have to be changed.

That's what we're understanding from reading calver and a big pdf on somerford minis.

[ljonez]

That must be what I had in the back of my head, sounds familiar.

[jb]

Yeah I think it might be - cheers for the suggestion though!

[dai9fxey]

Any news on the box problem JB?
Did you check the clearances on the primary gear IE; end float.?
The Clutch housing gaskets supplied today are not as thick as they used to be.
When you torque down the Clutch housing bolts / nuts the primary gear and idler gear get pinched (due to the thin gaskets) and that will cause all manner of problems with the gear change.
Once the engine gets hotter the mating surfaces expand causing further problems.
I've heard that in some cases 3 gaskets had to be used to get the correct clearances / end float.

[jb]

yep, checked end float on idler before refitting all ok. seem to remember somebody mentioning this in another thread( may well have been you dai) so i checked with the supplier of gaskets before purchase and he assured me thickness of gasket was compatible with oe gasket and that seems to be the case. when the weather warms up a bit gonna try to remove the diff in situ so i can have a peek at the selectors. hmmmmm.. jb snr

[jb]

box is out again. chips out of teeth on diff that weren't there before. think we will be sending it off for recon

[dai9fxey]

Oh Dear. Not good news.

[jb]

anybody had dealings with rtz minis ? have e-mailed them for prices . jb snr