No 3rd or 4th gear.....help!!! IT LIVES!!!

[knac1234]

Mark-those pictures are fantastic....very helpful for a rookie like me!

Gene-thanks....I don't think it will hurt to order another shifter as they are not that much, plus I can get a new set screw to fit the hole properly. I tend to agree with your analysis, again just because I was pretty easily able to move the shifter (and hence the ball in question) into the forks for 3rd/4th gear while 1st or 2nd was engaged by moving the shifter diagonally (easy to observe when looking at the mechanism identified in one of the pics I posted, pressing the clutch with one hand, and moving the shifter with my other hand).

Cheers,
Julian

[Apis Mellifera]

Is there a chance that because of your sloppy shifter ball, that when you're "shifted" out of 1 or 2, you're not all the way out? If the shaft is either a little toward 1 or 2 and the detent didn't center the shaft, that could lock out 3 and 4. Just brainstorming.

[knac1234]

Apis--Before giving up due to freezing conditions and snow yesterday after work, I got as far as removing the gear shift lever and starting to clean the crap off of the gearbox in preparation for removing the cover.

With the shifter removed, I was able to move the 1/2 shift fork with my finger in and out of gear. I could not do the same for the 3/4 shift fork. For the heck of it, before giving up for the day, I removed the plug that houses the 1/2 detent spring and ball....both were in there.

By Friday, I should have a new shift lever, all new detent springs and balls, synchro clips (6 so that I have backups), and a bunch of other bits related to those areas arriving in the mail. Weather should maybe hit 50 on Saturday, so that will be my next crack at it. I will know then whether I can pull this off, or whether to tow it to the shop to have someone else take care of it. I also ordered all new screws and fixings to reattach the floors and tunnel cover when ready....no more rusty junk there )

Cheers,
Julian

[ignotus]

Julian,

If you think the 1/2 selector was centered in the detents and you could not move the 3/4 selector I think it may be possible that the syncro is bad on 3/4. Just make sure the detents for 3/4 are working first.
Good luck!

gene

[knac1234]

Hello all,

Weather was good today, so, after a few more hours of removing rusted bolts, I was able to remove the seat box to gain full access to the tranny.

Another hour or so, and I cleaned up the top portion pretty well in order to take the cover off.

So, here is my dumb question of the day:

How do I get the top cover off (referring to the pics Mark posted in this thread)?

Referring to PIC 2-I have removed the 2 bolts of course that hold the gear lever and the two nuts you can see where studs are poking out only. Also removed the O/D gear lever assembly whose bracket was mounted to the top case. Do I need to remove those two slotted screws also?

Referring to PIC 1-Notice the bolt that is unscrewed but not removed (hits the bolt head of one of the bolts on the smaller cover).....does it need to come out too?

Thanks....never done this before, but am equipped with the proper parts and those long pliers!

Julian

[Terrys]

Referring to PIC 1-Notice the bolt that is unscrewed but not removed (hits the bolt head of one of the bolts on the smaller cover).....does it need to come out too?

You're all set Julian. That one is for the reverse stop, and doesn't need to be undone. The cover is on dowl pins, and because there is also a vertical joint, it may be difficult to break loose. Just tap with a small ball peen hammer, upward. It will come.

[knac1234]

Terry...thanks....will post pics at the end of the day of what I find!

On another note, I was catching up on some reading on this BBS and came across your barn thread. I am SO sorry. I cannot imagine how you feel about the damage to those unique vehicles. I suppose the only thing that is positive is that you or your family was not physically standing in there when it collapsed.

Cheers,
Julian

[Terrys]

Thanks Julian. I fell as badly for the guy who owned the barn as I do for loosing the cars. Just goes to show how bad this winter has been in this area. The Mini and Landy Rover are repairable, but the TD is a bit too badly damaged.

[knac1234]

PROGRESS!!!

Hello all,

Before letting you know about my progress, a question again!

The gear selector rods.....should I put grease into the "cups" where the ball at the end of the shift lever sits???? I cleaned them all up and oiled the inner forks, but those cups were nasty, and now are clean, and am thinking grease is needed?

So, here was my Sunday:

After taking some pics, looking at the mechanism, and taking a deep breath, I removed the gear selector forks from the tranny (some have called it a Chinese puzzle....hence my worry!).

I could then easily see the 3rd/4th synchro, and rotated it.....clip 1 OK, clip 2 OK, clip 3.....just a piece of metal that I quickly removed. Clearly it was jamming the mechanism as I could then select 3rd and 4th with my finger no problem

Ran into town and bought the recommended long 90 deg angled pliers and set off to replace the clip. Two hours later, after mangling two clips (and my fingers and knuckles), miraculously---and I have no idea how to describe it----I got the clip in. Clip looks properly installed, and I am still able to select 3rd and 4th gear

Drained the tranny oil to find the other half of the broken clip (which I did), and reassembled the tranny with all new detent balls, springs, and seals while I was in there.

So it APPEARS I will be successful, as the forks are back in and I can select all gears!

More to come as I need to install a new gearshift lever and of course put everything back together. To finish it off will be the proper spring and cup on the yellow knob lever that I ordered at the same time to replace the DPOs rigged spring and washer setup (and new screws and stainless nuts, bolts, and washers for the floors and seat box).

CHEERS,
Julian

[Terrys]

OUTSTANDING!

[albersj51]

Nice work, Julian! Also, thanks for following up. Too often (me included) we fix it and forget to follow up, which doesn't help the next person when trouble shooting and they do a search later on

[SeriesShorty]

Awesome!!! I'm glad yours went well and I can't wait to get started on mine.

[knac1234]

I am pretty confident it is going to work....will post when the whole thing is back together! Either way I owe all of you a big thanks for saving me some $$ fixing it.

Series shorty--good luck with yours, but get ready for busted knuckles and some pain----have plenty of beer on hand!

Any comments on the grease in the selector cups where the gear lever ball sits??

Cheers,
Julian

[Terrys]

yeah, grease it up. You don't have to go nuts, just enough to coat the whole area.

[Apis Mellifera]

Nice!

Once the top cover is installed and tightened, make sure the detent balls still move freely. I'd use copper grease (then again, I either copper grease or gasket sealer everything these days).