OK here it is as we got it gonna need some serious cleaning.
After removing the all the internals it had a lot of sludge in it, the mini gearbox shares its oil with the engine its also the oil pan.
here we have the parts removed from the case
In this next photo you can see two of the synchronizer cones the brass like parts pressed onto the gears, two of the three are bad one in the photo and the one on the input shaft not seen here and they are NLA new so the search begins to try and find good used.
When they were available they came installed on a new gear.
So I found a new old stock input shaft on ebay for $20.00 and got it one down one to go. After many more months of searching I decided it was time to try and make what I needed. The old synchronizer ring was carefully cut off the gear and sent to be analyzed it was made form a aluminum bronze. So I ordered a stick of aluminum bronze c954 from on line metals and went to work on the lathe and mill.
The part was roughed out and sized for a press fit to the gear it also gets staked onto the gear.
The notches around the outside where also cut on the mill with a dividing head at this time.
Then it was heated and installed on a chilled gear staked in place. Then the gear was centered in a four jaw chuck and the syncro taper cut to finished size.
The finished part.
It came out good!
Now onto the bearing issue, the mini transmission uses a double row ball bearing to support the output shaft the very early transmissions used a 62mm outside diameter bearing of cruise it is NLA.
And another Item I just cant seem to find a new old stock part for so tired of searching I decide that I can bore the case out on the mill to accept the new 65 mm outside dia bearing everything else is the same.
The case is bolted to the mill table and squared up I don't have a boring bar that is big enough, so some careful measuring and a fly cutter is used to bore it out.
Came out perfect now a through cleaning of case and all parts and reassembly can start.
OK so we left off with everything apart and needing cleaned, all parts and the case are now clean and ready for assembly.
