Manual gearbox - external components

Rebuilt or Repaired Gearbox Assemblies
Somerford Mini Ltd. offers a gearbox rebuilding and repair service, courtesy of 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 parts 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
Ill. No.	Part No.	Description	Qty. Rqd.	Remarks
1	2A3505B	GASKET, differential cover to gearbox case, upper	1
2	2A3506B	GASKET, differential cover to gearbox case, lower	1	1959-73 Saloon and Estate; 1960-75 Van and Pick Up. Direct or remote gearchange.
3	22G1836B	GASKET, differential 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, differential cover to gearbox case	2
6	22G1834	STUD, differential cover to gearbox case, long	4	Direct or remote gearchange.
	CHS2620	STUD, differential cover to gearbox case, long, RH	2	Rod gearchange.
	22G1834	STUD, differential cover to gearbox case, long, LH	2	Rod gearchange.
7	FNZ506	NUT	4
8	CHS522	STUD, differential cover to gearbox case, short	3
9	DAM7760	BOLT, flanged, differential cover to gearbox case, short	3	Alternative to stud from 1985 on.
10	FNZ505	NUT	3
11	LWZ305	WASHER, locking	3
12	22A74	LOCK TAB, large, differential cover to gearbox case	2	1959-62 direct gearchange.
	22A74	LOCK TAB, large, differential cover to gearbox case	1	Direct or remote gearchange.
13	42H500	LOCK TAB, large, differential cover to gearbox case	1	Rod gearchange.
14	22A251	LOCK TAB, small, differential cover to gearbox case	1	1962 on.
15	22A252	LOCK TAB, small, differential cover to gearbox case	1	1962-71 approx.
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
Ill. No.	Part No.	Description	Qty. Rqd.	Remarks
16	GUG705563GM	GASKET, flywheel housing to cylinder block/gearbox	1
17	22A97	DOWEL, flywheel housing to gearbox case	2
18	22A152	STUD, flywheel housing to gearbox case, long	6
19	DAM7759	BOLT, flanged, flywheel housing to gearbox case, long	6	Alternative to stud from 1985 on.
20	53K547	STUD, flywheel housing to gearbox case, short	3
21	DAM7756	BOLT, flanged, flywheel housing to gearbox case, short	3	Alternative to stud from 1985 on; not 1275cc.
	DAM7756	BOLT, flanged, flywheel housing to gearbox case, short	1	Alternative to stud from 1985 on; 1275cc.
	DAM7757	BOLT, flanged, flywheel housing to gearbox case, short	2	Alternative to stud from 1985 on; 1275cc.
For nuts, washers and lock tabs for the above studs, plus screws, bolts and lock tabs used to attach the flywheel housing to the cylinder block, please see the 'Flywheel Housing and Clutch Cover' section.

Speedometer Pinion Housing Attachment
Ill. No.	Part No.	Description	Qty. Rqd.	Remarks
22	DAM5219	HOUSING, speedometer pinion	1
23	GUG705569GM	GASKET, pinion housing to gearbox case	1
24	22A13	DOWEL, pinion housing to gearbox case	2
25	SH505091	SCREW, coarse thread, housing to gearbox case	5
26	LWZ305	WASHER, locking	5
27	53K1474	STUD, pinion housing to gearbox case	3
28	DAM7761	BOLT, flanged, pinion housing to gearbox case	3	Alternative to stud from 1985 on.
29	53K551	STUD, engine mounting to pinion housing	1	Not 850 models, 1959-68.
	53K545	STUD, engine mounting to pinion housing	1	850 models, 1959-68.
30	FNZ505	NUT	4
31	LWZ305	WASHER, locking	4
32	2A3626	END PLATE, pinion housing	1
33	GUG705564GM	GASKET, end plate to pinion housing	1
34	SH504061	SCREW, coarse, end plate to pinion housing	2
35	LWZ304	WASHER, locking	2

Cylinder Block Attachment
Ill. No.	Part No.	Description	Qty. Rqd.	Remarks
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, gearbox case to thick flanged cylinder block	2	Not Cooper or Cooper S models, 1961-67.
	FHS2409	STUD, gearbox case to thin flanged cylinder block	2	Cooper and Cooper S models, 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
Ill. No.	Part No.	Description	Qty. Rqd.	Remarks
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 gearchange.
53	AHU1672	OIL SEAL, selector shaft, in differential cover	1	1973 on Saloon; 1973-82 Estate; 1976-84 Van and Pick Up. Rod gearchange.
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 gearchange.

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. We 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.
Ill. No.	Part No.	Description	Qty. Rqd.	Remarks
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., 3/4" int. dia.)	1	1968-79, 4 synchro gearbox.
	AHU1707	BEARING, idler gear (1 3/8" ext. dia., 7/8" int. dia.)	1	1979 on, 4 synchro gearbox.
	DAM3745	BEARING, idler gear, special, with sleeve (1 3/8" ext. dia., 3/4" int. dia.)	1	For use, see note below.
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 allow 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 part for those wanting to mix and match their gearbox, idler and drive gears.

Ill. No.	Part No.	Description	Qty. Rqd.	Remarks
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

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Manual gearbox - external components

USE: LWZ204

SET SCREW-5/16 UNC x 1 1/8''

USE: LWZ205

SET SCREW-1/4'' UNF x 1''

WASHER-SUMP PLUG/ OIL PIPE BANJO BOLT/SERVO HOSE ETC

NUT-5/16 UNF-HIGH TENSILE

NUT-3/8 UNF-HIGH TENSILE (GRADE 3)

BEARING-IDLER GEAR-3 SYNCHRO / TOP SUSPENSION ARM

NUT - 1/4" UNF

BOLT- 1/4 UNF x 1 5/8''

WASHER-PLAIN - 1/4" x 9/16" O.D.

We accept