Tuesday, June 14, 2016


If you're old enough, you get the title.

Finishing up reassembly...  First, the gearbox extension.  I cleaned it up nice.

The extension doesn't have too many parts:

  • The linkage connecting the shifter and the selector forks;
  • The rear oil seal and driveshaft yoke bushing;
  • The speedo drive;
  • The filler plug.

I installed the linkage.  No problem.

Then, I reamed out the new propellor shaft (drive shaft, LOL) bushing.  The bushing has to be reamed so the yoke will fit into the housing over the end of the third motion shaft.  I'm a bit nervous.  Not because I think I did a bad job, but I'm not sure there is enough surface left on the bushing for the long term.  I had to take a lot off.  The original bushing was bronze (or copper, but I think bronze) and the new one is bronze plated steel.  I can see a bit of steel on the edges of the bushing.

It turns out a 22mm deep well socket and 1 1/2 wraps of 80 grit PSA sandpaper makes a perfect size to ream the bushing.  After I got it close, I polished it up and it is exactly the right size to allow the yoke to fit without binding or being sloppy.  But it's close.  

Anyhow, I fitted the bushing and the rear oil seal.  The old seal was hard like a rock.  This won't leak now.

Then, the speedo drive. I replaced the oil seal inside the drive.  This was not easy to remove, and I had to Dremel it out without damaging the housing.  But I did it.

After all that, it's a matter of fitting the gasket and attaching the extension.  All that pickiness in lining up the bearing plate paid off; it fit first time and bolted down like I had never touched it.

Last, but certainly not least comes the remote control unit.  I did not disassemble this one, just cleaned it up.  It has plugs on each end I'd have to punch out to remove the shaft, and it wasn't worth messing with it.

So I installed the little plastic cup that connects the shifter extension to the linkage (it fits on the ball on the left in the above picture), installed the gaskets (with sealant as required), and bolted it on.

The remote housing has two anti-rattle plungers.  I guess it rattles.  I cleaned them up, too.  Here's where they go in the housing; one in the upper right, and the other in the lower left hole.

That does it for the back of the gearbox.

One last chore--fitting the release bearing.  The bearing arm has a bush that I replaced, and it's like a two-pronged fork that holds the bearing with these really interesting clips that allegedly allow you to replace the bearing without removing the arm.  I've never had luck with that.  Besides the arm, there's some rubber bits for the inspection hole, a blanking plate where you'd install the release bearing arm on right-hand drive cars, and the boot over the release bearing arm.  Oh, and the ring, cup and spring for the shifter arm, too.

It's pretty easy to install the bearing arm.  I installed the rubber boot first, and used some WD-40 to make it easier to push the arm through the hole in the boot.  I found that you have to fit the release bearing over the input shaft first, though.

The result is an empty parts box...

And a fully assembled transmission.  According to Haynes, "The gearbox is now ready to be refitted to the car."

No, that's not the same picture as when I started all of this.  It used to look like this:

See the difference?

Now, all I need to do is find the shift lever.  Dammit.

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