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202tonner Offline
#1 Posted : Friday, 21 December 2018 7:53:07 PM(UTC)
202tonner

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Looking for some info on rebuilding a 3 speed all synchro box. It's for a 202 HJ tonner.
The Gregory's book runs through what to do quite well but there are a couple of points where more info would be nice.

There is a bearing lock nut on the front (EDIT] input shaft bearing which apparently needs a special tool. It this really needed or can another tool be substituted or a custom one made easily?

How difficult are the bearings on the mainshaft [EDIT] and input shaft to remove? Does it need a press or can long armed pullers or slide hammers do the job. And for installation can a suitably sized piece of pipe be used to drift the inner race to put the bearings on or is a fair bit of force with a press needed?

With regards to parts, are the layshaft clusters still available? If not would rebuilding a HQ racing box and putting a 6 cyl [EDIT] input shaft in it work? This might give a cluster which is in better shape than one from a 40yo box.

I have measured the [EDIT] input shaft on a 6cyl box and it protrudes 88mm for the bearing retainer or 170 mm from the gearbox casing. How much longer is the V8 [EDIT] input shaft? Is it a matter of a couple of mm or a couple of inches? Knowing this would help identifying them. [EDIT: See below; V8 measurement is 195mm]

Any other tips from anyone who has done one? I've never done a gearbox before so all help is greatly appreciated. TIA.

Edited by user Friday, 21 December 2018 10:51:42 PM(UTC)  | Reason: Changed "mainshaft" to "input shaft" to use correct terms

HK1837 Offline
#2 Posted : Friday, 21 December 2018 8:16:40 PM(UTC)
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What you are calling a mainshaft is the input shaft or clutch gear. You have an old box with a slinger type oil seal. By now my guess is the case hardening on the inside of the input shaft is toast. You can buy a new one but it will have a neoprene seal which will need a new cover too (but the clutch bearing slides on). The bearing on this later type is held on with a snap ring. The 6cyl 3spd input shaft is the same as an M22 4spd.
Changing the bearing on the input shaft and the one at the back of the mainshaft isn’t that hard.
As for finding parts, 4spd bits are easy so at least you are right for most small parts and synchros. Not sure about 1st and 2nd gears, selectors, cluster or mainshaft.

Take your box to this guy if you are in Sydney:
https://www.ebay.com.au/...38528:g:oq8AAMXQ2UVQ8ene

There is a dude in Toowoomba too, he came down to my place in Lake Macquarie a few weeks ago to pick up about 3-400kg of Aussie 4spd bits and he rebuilds them too.

Here is a brand new one:
https://www.ebay.com.au/...431c3:g:aA4AAOSwteFb9oLl

Edited by user Friday, 21 December 2018 8:24:32 PM(UTC)  | Reason: Not specified

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202tonner Offline
#3 Posted : Friday, 21 December 2018 10:49:20 PM(UTC)
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Thank you very much for that info.

I figure that every component in any box I find is going to be toast so the availability of anything new is a bonus. The info on the M22 input shaft is invaluable. Thanks.

I'm in SA and there are a couple of gearbox specialists which get recommended again and again but a full recondition costs $$$. Admittedly I would get a box that would last for a decade but it is more fun, and cheaper, to fiddle around and learn something new. Even if I don't know what I'm doing!

For info the V8 input shafts measure about 195mm from the gearbox to the end of the shaft (found this searching for M22 info) and the 6cyl ones measure about 170mm.

Sounds like a rebuild isn't too hard so I'll give it a go. Thanks again.
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