Refitting gearbox problem - no drive

[Russ_T]

Hello,

I've just spent my Christmas break replacing the engine in my '53 Cooper, using my old gearbox and clutch.

I put it all back together, started her up, and she sounded much healthier. I went to put it in gear to drive off and nothing!!!

The symptoms are:

• Feels like it's going into gear fine.
• Release the clutch and no drive, but a slight whiring sound.
• You can select a gear without the clutch.
• Jacking up the front of the car if you spin one wheel the other rotates the opposite way (so the diff is ok).
• The clutch has loads of life left in it.
• I have tried unbolting the clutch slave cylinder in case it was lifting the clutch.
• The engine starts fine so flywheel to engine is no problem.

From the above it seems ok between the diff and the gearbox, or the flywheel and the gearbox output shaft.

It's as if the clutch is permanently disenganged. I wonder if there are different flywheels or release bearings depending on model year? Could the bearing be on backwards or something so as I bolt the gearbox up it releases the clutch?

Has anyone got any ideas please? It takes me best part of a day to get the gearbox out and in again, and I've already done it twice with no luck, next time I do it I'd like it to work again.

Thanks very much,

Russ

[mab01uk]

As you probably know the early Midland gearbox is known for failure but seems strange it was ok before your engine swap. Not sure this is relevant for your case, but one of the known failures is no drive....when the diff gear starts spinning on its shaft, I believe it was bonded rather than mechanically keyed to shaft but is prone to failure of the 'bond'.

More on Midland gearboxes here:
Early MINI Rover Midland Gearbox - Forums

You could also try Minigearboxes for advice, they are usually pretty helpful:
(Ask for John Tee who is also a member of Mini2)
mini gearbox, gear fix - Mini recon gearboxes | BMW MINI cheap gearboxes

[Russ_T]

I was not aware that they fail, damn, it's going to look like I broke it now

The gearbox was lovely and the clutch, I don't understand it.

John is going to give me a ring back when he's free The lady said she's heard of them go when a clutch is changed. Knowing that they're rubbish should I be doing a full Getrag conversion though with the added expense that brings?

Thanks for your help

[mab01uk]

If it does turn out to be the gearbox John does the 6-speed Getrag MCS conversion for a pretty good price but as you are obviously good at diy mechanics you would only need to buy the box and other parts as required.

If or when my current Midland 5-speed box goes I shall certainly be going for the 6-speed Getrag conversion. Well worth the extra cost I think, especially if keeping your Mini for the longer term as I intend.

Most Midland boxes do seem to have a very nice gear change though.....at least when they are working ok!

[Russ_T]

I would be tempted, but it's my gfs car and it's been quite expensive with the engine change and other parts. As she's not really into cars I don't think I could get it sanctioned Booo

What do you think all the parts would cost? I can get a gearbox/diff for £230 and probably flog my current one (like you say, lovely gear change, shame about the diff).

No plans to change the mini any time soon, bah, wish you hadn't planted the idea in my head now

Cheers

[Russ_T]

Actually I've just talked myself out of it. One for the future!

The car is lovely, but every time I think of upgrading it I just think "Go buy a Cooper S"... There were also improvements after 2004 (although I prefer the old looks) and you begin to wonder if there is any point doing this one up, just buy a newer faster one and get another Chili pack/Aero kit model.

[mab01uk]

Quote: Originally Posted by Russ_T (original)

Actually I've just talked myself out of it. One for the future!

The car is lovely, but every time I think of upgrading it I just think "Go buy a Cooper S"... There were also improvements after 2004 (although I prefer the old looks) and you begin to wonder if there is any point doing this one up, just buy a newer faster one and get another Chili pack/Aero kit model.

True, especially if gfs car!..........keep us informed of what the solution to the problem turns out to be.

[Russ_T]

Thanks, will do.

One thing that has sprung to mind is maybe the planetary gears in the diff have dropped or moved. I wouldn't have thought the driveshafts would go in if that was the case, but apparently on some diffs that can happen. Usually you're suppose to put a bung in to stop that happening, tonight I'll have the gearbox off and see if the diff is lined up inside or not. Might have to split the diff down, that way at least I can confirm that the gear is no longer bonded to the shaft

Cheers

[Russ_T]

Fixed!!

Ok a bit embarassing, but pleasing to find. The o/s outer cv joint wasn't together properly, must have popped out at some point when we were heaving things around. The cv boot was enough to spin the drive when no wheels were on the floor, but under power of course it just span. It wasn't obvious to spot until I heard it catching as I was messing about with the other side. Slid the boot back to look inside and it's easy to op it out and not put it back in properly, first time I rebuilt it I was sure i had it in and it wasn't so next time I looked with the boot off.

Anyway put the rest of the car back together tonight and happy days!

Cheers

[mab01uk]

Nice easy fix and much cheaper!
Thought it was strange a good working Midland gearbox should suddenly fail while swapping over the engine.

Make sure you change the MTF94 gearbox oil as it helps extends the life of what can be a troublesome gearbox, even though BMW quote it as 'filled for life!"

[Russ_T]

Kinda...

I just finished the rebuild, have a minor oil leak from I think the filter housing so probably the rubber is trapped, was going to investigate tomorrow.

Anyway drove out the drive, down the hill, turned left at the bottom of the road and the bloody driveshaft popped out again! So had to push it back up the hill Anyway we can't have put the hub end of the driveshaft on properly so it popped that end rather than slide up and down in the cup on the diff end.

So tomorrow I'll take the whole driveshaft off (having drained the gearbox for the 4th time) and get it in the vice, and put the hub end back on until I know it's properly clipped in. Then once it's all back together I'll give it some grief on my road rather than at the bottom of the hill

I couldn't find that oil easily so got some Total 75/80 which seems to be an equivalent... I hope.

Cheers

[mab01uk]

Only place I could find to buy the MTF94 was a Land Rover Dealer next door to my local MINI Dealer who did not stock it! Hope you have more luck tomorrow!