My turn for a gearbox rebuild

I started my gearbox rebuild adventure today. I could only go as far as pulling the seat box out though as I have 3 cracked ribs and can't bend/lift very well. I have a friend coming in the morning to finish the removal for me.

The gearbox will be interesting as it is a bugger to shift into second from 1st, don't waste time trying to go from 3rd to 2nd. 3rd gear sounds like a blender full of rocks. 4th is fine. I am interested to see what awaits in the gearbox. I can't find any markings other than a Spanish serial number to identify the box as to its suffix. The slave cylinder is on the drivers side(LHD) parallel to the ground and I read here that at least makes the bell housing a Series 3. Well here are the first stage of photos. I will post more as I get more work done. Cheers.

number is usually stamped on top were you have a number or on front top edge of t/box ,front output housing isnt std looks like it was off a santana type ,even if you cant find a number you can identify suffix by the gears and layshaft

jamesmartin said:

number is usually stamped on top were you have a number or on front top edge of t/box ,front output housing isnt std looks like it was off a santana type ,even if you cant find a number you can identify suffix by the gears and layshaft

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It is a Santana 109 so that probably explains the output housing difference. I might have pictures of the inside tomorrow, just depends on how I do getting the outside of it degreased first.

A little progress today. Gearbox is out and what a mess it is. All the oil from the gearbox has been working its way into the bell housing. Even the boss for the slave cylinder was full. There were lots of silver flakes in the oil. The input shaft has 3-5mm of play in and out and about 1-2mm up and down. I think the bearings have seen better days. I will post more as I get to it but have to work for the next week straight so won't get much done. Enjoy the pictures.

If i was you I would replace the clutch and the rear bearing seal as it might leak too

That bell housing looks disgusting!

It's amazing how much abuse/damage they'll take before throwing in the towel!

I thought that release bearing would be good still, I challenge you to find one more well lubricated This old girl was still running and moving down the road. I just couldn't handle the noise anymore and tired of the "little tricks" to shift into second. The inside of the gearbox should be even more interesting.

looks like its had water in the oil

I don't think it is water unless condensation in bell housing. My thoughts were clutch dust and there is lots of silver flakes in it. Trying to find an investor to buy the mineral rights

that looks more like water mixed in the oil but youll see if it looks similar inside,take a good few pics as you dissemble it

jamesmartin said:

that looks more like water mixed in the oil but youll see if it looks similar inside,take a good few pics as you dissemble it

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Most definitely.

A few more pictures lads. The securing bolt on the bottom shaft is broke and obviously the upper bearing is in need of change.

Did you find the head of the layshaft bolt?
Never seen that one before(in my vast experience of 2 gearbox builds). Could this box have been rebuilt before and some one over torqued the bolt?

SpringDon said:

Did you find the head of the layshaft bolt?
Never seen that one before(in my vast experience of 2 gearbox builds). Could this box have been rebuilt before and some one over torqued the bolt?

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The head of the bolt is in the third picture down under the washer and oil. Somebody has been in it and probably did over torque the bolt. All the sync rows are shot, bearings needed, looks like most of the gears and the layshaft. Oh and the bearing cover in the bell housing is cracked. Anybody have the internals for a series 3 box they want to mail to Spain? Transfer box looks good for what I have seen so far. Haven't pulled it off yet but it will get new bearings as well.

Looking at the internals what suffix would you guys say this is? I found a C stamped on one of the shafts.
Now for the pictures.

Probably suffix c but count the teeth on the 1st mainshaft gear. 31 suffix d or c. 35 a or b.

That looks well broken! Where did the plastic caged bearing come from (pic 7ish). All the bearing I found were metal caged, only the replacement parts had plastic. Don't really like plastic ones but I don't know if that's just predjudice.

SpringDon said:

Did you find the head of the layshaft bolt?
Never seen that one before(in my vast experience of 2 gearbox builds). Could this box have been rebuilt before and some one over torqued the bolt?

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its surprisingly not that uncommon in series 3 as well as 2s

SpringDon said:

Probably suffix c but count the teeth on the 1st mainshaft gear. 31 suffix d or c. 35 a or b.

That looks well broken! Where did the plastic caged bearing come from (pic 7ish). All the bearing I found were metal caged, only the replacement parts had plastic. Don't really like plastic ones but I don't know if that's just predjudice.

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front end of mainshaft into input shaft (cp shaft )theyve been plastic caged since the 70s

box has had water in it ,could be condensation over a long time

Going to do more measuring and inspecting tomorrow. Hopefully I can salvage a few more parts but I am skeptical. I would just go buy another gearbox but the cheapest used one I have found here is 300 euros and even though it is a "good gearbox" I think I would end up in the same boat. Will be scrounging ebay where I can and ordering genuine when i need them. I will keep posting findings and pictures. Cheers