Car transmission rebuild.

[dawesy]

Thought I'd share the rebuild I've just done on my MR2
Enjoyed doing this. Can't wait to put it in and put it to use.
It came out of the car looking like this


 :no:

The casing was stripped down and sent for Vapour blasting and came back looking like this



I also sent the bolts and brackets to a local platers and had them Re-gold passivated



Looking at some of the bearings, I wasn't happy with them. They were smooth enough but pitting was evident. I priced up the Two taper bearings on the output shaft and the roller on the input shaft and it came to over £500!
A friend at work put me onto Cobra Transmissions in the States who do complete rebuild kits or bearing and seal kits. As I'd already Bought a new first gear synchro (the old one had cracked leading to the crunchy first) I went with the bearing and seal kit, This comprises both Diff bearings, Both output shaft bearings and both input shaft bearings, Plus Driveshaft, Input shaft and selector seals. Came in at just under £500 incl shipping.



Assembly was started after everything was stripped and cleaned.

(Output shaft)


(New outer races installed)


Then all Bearing preloads checked and found to be well within tolerance

(Shafts and selectors installed)




Correct Threebond sealant used




Re-assembling the 5th gear syncro lead to this

Its a complete PITA to get together, However I won!!



And that was that. Some final shots all back together. I'm just waiting for the bellows on the selector to come as mine were shot.









Thanks for looking.

[John Rudd]

Kewl....

Stripped and rebuilt a few gearboxes in my time but not to the point of changing bearings.....Although I've changed syncro parts that were worn,replacing them from salvaged boxes.....
The old Borg Warner overdrive units were easy too.....

[DavidA]

It's a long time since stripped and rebuilt a gear box. In fact,  since I stopped working on Fords.

Citroen, Peugeot and Renault just seem to keep on going.

Dave.

[NormanV]

I had to rebuild the gearbox on my Landrover many years ago due to a broken layshaft. For the first few hours that I drove it after the rebuild I was delighted with the precise snappy gear changes but then it went back to its usual floppy self.

[Arbalist]

Nice job. I can't believe the price of the bearings though, what are they made from Gold?!

[Stilldrillin]

That's much too nice, to put under a car! 

Well done Lee! 

David D

[dawesy]

Thanks guys.
Stripping it wasn't pleasant, there's something repugnant about old gear oil
Yeah I was shocked too. I tried a few bearing suppliers but met a dead end. I seems that these are specific to this gearbox. Simplybearings were told by Nachi the manufacturer that they couldn't supply them to them! Talk about a monopoly. 

[Lykle]

This reminds me of the first time I did anything mechanical.
A friend gave me a cardboard box filled with the parts of a Mini gearbox.
Have a go, he said.

Took me a while, but eventually, it came together in working order. Or so I thought. I found one more part, a little pin, hiding in the box. Took it all apart,m put it back together again with pin. It worked.
Took me about a month, as I had never seen a gearbox, let alone the parts.

This job, is on a completely different level, great work!

[vtsteam]

Very fine work, Dawesy! That thing is beautiful. 

[dawesy]

Thank you.
I like puzzles. I once had to do a car for a friend who had taken it to a garage. They had stripped the top half off but for some reason (can't remember what now) they wouldn't carry on. So it came to me with half the engine in a box in the boot. Figured it out eventually
Try and get it fitted this weekend weather permitting.