Manual Gearbox - 3 Synchro Internal Components

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12 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - 3 Synchro Internal Components
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

The 3 Synchro Gearbox thing to remember here is don’t embark on a 3 synchro gearbox rebuild until (a) you’re absolutely sure
you have the parts you need; and (b) you’ve weighed up seriously the benefits of sourcing another, better
1959-68
condition, gearbox instead. You have been war ned...
Fitted to all Minis between 1959 and 1968, the 3 synchro gearbox is so called because synchromesh is
only available on 2nd, 3rd and 4th gears, 1st gear being of the ‘crash’ engagement type. Probably the
Close Ratio and Straight Cut Gears
most common fault on this gearbox is jumping out of first gear, followed closely by laygear bearing and
Close ratio straight cut gear sets are available to build into gearboxes with B Type Gears components, as
layshaft failure. A proper first speed gear was inserted in the gearbox in 1968, at last receiving the
a special order. Please contact Somerford Mini for details. Similarly, please contact us if you have
great benefit of synchromesh engagement; this gearbox is known as the 4 synchro and its internal
factory-optional (Special Tuning) helical close ratio, straight cut close ratio or straight cut
components are covered in the next section of the catalogue.
standard ratio gears in your gearbox and you require replacement parts.
If you’ve not been inside a 3 synchro Mini gearbox before or you can’t remember when you last did,
Reverse Idler Gear
please read these notes carefully - they could save you a lot of heartache. The gearbo x internal
1 22A377 REVERSE IDLER, with bush, 18 teeth 1 1959-64; 848 models, Cone Synchro
components were revised several times , with the changes being introduced at broadly the same times
and A Type gears.
across all of the A series engined cars in the BMC range . Essentially, these revisions boil down to three
types of gearbox (with a handful of components being awkward exceptions to the rule, of course... w e’ll 1961-62; 997 Cooper, Cone Synchro.
1962-63; 997 Cooper, A Type gears .
explain those as best we can as we go along).
1963; 997 Cooper, A Type gears .
22G202 REVERSE IDLER, with bush, 18 teeth 1 1963-64; 997/998 Cooper, 1071
The first 3 synchro gearbox fitted to the Mini is known as the ‘cone synchromesh’ gearbox, because of
Cooper S , A Type gears with B Type
its use of cones to aid gearchanging rather than the more efficient baulk rings, which arrived in 1962.
The next change occurred in 1963 or 1964 (depending on model) when the angles of the gear teeth 1st/2nd synchroniser and reverse.
1964-68; 848 and 998 (not Cooper)
were changed to quieten the baulk ring gearbox. The modified gears w ere known as B Type gears , the
models, B Type gears .
1962-63 gears retrospectively becoming known as A Type gears . So there you have it: 1959-62 Cone
1964-68; 998 Cooper, 970/1071/1275
Synchromesh gearbox, 1962-63/64 A Type Gears gearbo x and 1963/64-68 B Type Gears gearbox (plus, in
Cooper S, B Type gears .
1963-64, an A Type gearbox with B Type 1st/2nd synchroniser and reverse idler...!).
2 2A3475 BUSH, reverse idler 1
3 DAM8038 SHAFT, reverse idler 1
Gearbox Identification
Identifying your 3 synchro gearbox can be a ver y complicated process, bourne out by the unfor tunately
Laygear
necessarily complex guidelines below.
4 22A381 LAYGEAR, 13/19/24/28 teeth 1 1959-64; 848 models, Cone Synchro
Between the three 3 synchro gearbox types, many, many components are not interchangeable. This and A Type gears.
22A350 LAYGEAR, 13/19/23/26 teeth 1 1961-62; 997 Cooper, Cone Synchro.
makes it especially important to identify your gearbox before ordering par ts, which can be difficult,
22G76 LAYGEAR, 13/19/23/26 teeth 1 1962-63; 997 Cooper, A Type gears .
particularly when trying to work out whether you have A or B Type gears . Originally, gearbox cases
22G197 LAYGEAR, 13/19/23/26 teeth 1 1963; 997 Cooper, A Type gears .
were stamped with a part number denoting the gear types within and the model application; however
22G204 LAYGEAR, 13/19/23/26 teeth 1 1963-64; 997/998 Cooper, 1071
this has become quite irrelevant over the years as gearboxes have been rebuilt, very often with different
components to overcome the lack of original parts availability. Cooper S , A Type gears with B Type
1st/2nd synchroniser and reverse.
22G231 LAYGEAR, 13/19/24/28 teeth 1 1964-68; 848 and 998 (not Cooper)
The only surefire way to identify the gearbox nowadays is to inspect the internals with a check list to
models, B Type gears .
hand, paying particular attention to:
22G1100 LAYGEAR, 13/19/23/26 teeth 1 1964-68; 998 Cooper, 970/1071/1275
(i) the presence of synchro cones or baulk rings (denoting a Cone Synchro box in the first instance and
an A Type or B Type box in the second); Cooper S, B Type gears .
5 22A1371 LAYSHAFT 1
(ii) If baulk rings are present, establish whether the second and third gears run on bushes (the bush
6 2A3581 PLATE, locating reverse idler shaft/layshaft 1
interlocking ring being visible between the two gears on the mainshaft gear cluster) or bearings . A Type
7 88G396 BEARING, needle roller, laygear 2
gearboxes except in the 1963 Cooper 997 run on bushes; the second and third gears in A Type
8 22G277 DISTANCE PIECE, bearing 1
gearboxes in the 1963 Cooper 997 run on bearings, as is the case with the similarly shor t-lived Cooper
and Cooper S gearbox with hybrid A/B Type gears and all gearboxes with B Type gears. 9 22G278 CIRCLIP, bearing retaining 2
10 88G325 WASHER, thr ust, large 1 0.123-0.124" (3.12-3.14mm).
(iii) Count the number of teeth on the laygear cluster. A combination of 13/19/24/28 teeth is the
88G326 WASHER, thr ust, large 1 0.125-0.126" (3.17-3.20mm).
regular set-up for non Cooper models and 13/19/23/26 for Cooper. Other combinations were available
88G327 WASHER, thr ust, large 1 0.127-0.128" (3.22-3.25mm).
only as Special Tuning options.
88G328 WASHER, thr ust, large 1 0.130-0.131" (3.30-3.32mm).
(iv) Are the laygear bearing circlips on the outside or inside of the bearings? Cone Synchro and A Type
gears except 1963 Cooper 997 use outside laygear bearing circlips, whereas A Type gearbox in the 1963 11 88G324 WASHER, thr ust, small 1
Cooper 997, the hybrid A/B Type gearbox and B Type gearboxes use inside circlips.
1st Motion Shaft
12 22A88 SHAFT, 1st motion, 19 teeth, with cone 1 1959-62; 848 models, Cone Synchro.
The laygear should tell you which combination of gears you have... we say ‘should’ because the laygear
22A588 SHAFT, 1st motion, 19 teeth 1 1962-64; 848 models, A Type gears.
part number was traditionally stamped on the component between the lar gest and second largest gears,
but some reproduction gears (mostly in the case of 22G1100) don’t have this stamping. Identifying 22A257 SHAFT, 1st motion, 20 teeth, with cone 1 1961-62; 997 Cooper, Cone Synchro.
22A416 SHAFT, 1st motion, 20 teeth 1 1962-63; 997 Cooper, A Type gears .
your laygear allows you to work out what other gears have been used in the gearbox, since they were
22A592 SHAFT, 1st motion, 20 teeth 1 1963; 997 Cooper, A Type gears .
designed to go together as matched gear sets and are usually not interchangeable. For this reason, all
1963-64; 997/998 Cooper, 1071
the other major components in this section use the application remarks shown alongside the laygears -
Cooper S , A Type gears with B Type
even if it’s a bit long-winded sometimes, it positively matches the sets together.
1st/2nd synchroniser and reverse.
22A979 SHAFT, 1st motion, 19 teeth 1 1964-68; 848 and 998 (not Cooper)
Be careful with gearboxes in 848 models and 997 Coopers using A Type gears , though - some have been
models, B Type gears .
converted from cone synchro to baulk ring A Type gears, retaining the original laygear ; some other
22A982 SHAFT, 1st motion, 20 teeth 1 1964-68; 998 Cooper, 970/1071/1275
components used in cone to baulk ring converted gearboxes are unique and most are not listed here
Cooper S, B Type gears .
(this catalogue section is complicated enough!). The 22G1100 laygear, incidentally, was for a short
period at the start of its life known as and stamped as 22G232. Lastly, if you find 22G83 or 22G714 13 2A3693 CONE, synchronising 1 For 22A88 and 22A257 1st motion shafts.
Note that synchro cones have to be shrunk onto their respective gears and then finally machined - not a
on your laygear, you have an Austin/Morris 1100 or 1300 gearbox, not a Mini one.
task for most home-based Mini restorers.
Parts Availability
14 22G2033 RING, baulk 1 For all other 1st motion shafts .
Unfortunately, par ts availability ranges from almost hopeless (Cone Synchromesh and A Type gears)
through to pretty awful (B Type gears) and this situation is unlikely to improve greatly in the future. 15 22G314 BEARING, 1st to 3rd motion shaft 1 For 22A88, 22A588, 22A257 and
22A416 1st motion shafts .
The B Type gears do, however, benefit marginally from the fact that the MG Midget continued to use
CHM172 BEARING, needle roller, 1st to 3rd 1 For 22A592, 22A979 and 22A982
versions of them until 1974, which slightly increases parts demand and availability. Many parts listed in
motion shaft 1st motion shafts.
this section are therefore shown only as a matter of reference.
16 2A3709 BEARING, 1st motion shaft 1 In gearbox case.
We will always do our utmost to help you seek out parts for your gearbox, but by rule of thumb the 17 2A3710 CIRCLIP, bearing retaining 1 0.094-0.096" (2.39-2.44mm)
2A3711 CIRCLIP, bearing retaining 1 0.097-0.099" (2.46-2.51mm)

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Manual Gearbox - 3 Synchro Internal Components

© Copyright Somerford Mini Limited

14 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - 3 Synchro Internal Components
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

1st Motion Shaft (Continued) 34 2A3298 BUSH, 2nd speed gear 1 For 22A90 or 22A582 2nd gears.
For the 1st motion shaft bearing supporting the nose of the shaft in the flywheel housing, please see 35 22G374 RING, interlocking, 2nd/3rd gear bushes1 For 22A90 or 22A582 2nd gears.
the ‘Flywheel Housing and Clutch Cover’ section in the Somerford Mini Catalogue. 36 22G186 COLLAR, locking, 2nd speed gear 1 For 22G194 or 22A980 2nd gears.
37 22G149 BEARING, needle roller, 2nd speed gear 26 For 22G194 or 22A980 2nd gears.
3rd Motion Shaft 38 22G157 WASHER, 2nd speed gear locking collar 2 For 22G194 or 22A980 2nd gears.
18 2A3719 SHAFT, 3rd motion 1 1959-61; 848 models, Cone Synchro. 39 22A495 PEG, 2nd speed gear locking collar 1 For 22G194 or 22A980 2nd gears.
1961; 997 Cooper, Cone Synchro. 40 22G154 SPRING, 2nd speed gear locking collar 1 For 22G194 or 22A980 2nd gears.
22A425 SHAFT, 3rd motion 1 1961-62; 848 models, Cone Synchro.
1961-62; 997 Cooper, Cone Synchro. 3rd Gear
22A421 SHAFT, 3rd motion 1 1959-62; Cone Synchro to baulk ring 41 22A89 GEAR, 3rd speed, 23 teeth, with cone 1 1959-62; 848 models, Cone Synchro.
synchro conversion item. 22A583 GEAR, 3rd speed, 23 teeth 1 1962-64; 848 models, A Type gears.
22G70 SHAFT, 3rd motion 1 1962-64; 848 models, A Type gears . 22A261 GEAR, 3rd speed, 24 teeth, with cone 1 1961-62; 997 Cooper, Cone Synchro.
1962-63; 997 Cooper, A Type gears. 22A415 GEAR, 3rd speed, 24 teeth 1 1962-63; 997 Cooper, A Type gears .
1963; 997 Cooper, A Type gears . 22G195 GEAR, 3rd speed, 24 teeth 1 1963; 997 Cooper, A Type gears .
1963-64; 997/998 Cooper, 1071 1963-64; 997/998 Cooper, 1071
Cooper S , A Type gears with B Type Cooper S , A Type gears with B Type
1st/2nd synchroniser and reverse. 1st/2nd synchroniser and reverse.
22G392 SHAFT, 3rd motion 1 1964-68; 848 and 998 (not Cooper) 22A981 GEAR, 3rd speed, 23 teeth 1 1964-68; 848 and 998 (not Cooper)
models, B Type gears. models, B Type gears .
1964-68; 998 Cooper, 970/1071/1275 22A983 GEAR, 3rd speed, 24 teeth 1 1964-68; 998 Cooper, 970/1071/1275
Cooper S, B Type gears . Cooper S, B Type gears .
19 22A422 WASHER, spacing 1 1959-62; Cone Synchro to baulk ring 42 2A3693 CONE, synchronising 1 For 22A89 or 22A261 2nd speed gears.
synchro conversion item. 43 22G2033 RING, baulk 1 For all other 2nd speed gears.
20 2A3712 BEARING, 3rd motion shaft 1 For 2A3719, 22A425 or 22A421 shafts. 44 2A3290 BUSH, 3rd speed gear 1 For 22A89, 22A583, 22A261 or
22A575 BEARING, 3rd motion shaft 1 1959-62; Cone Synchro to baulk ring 22A415 3rd speed gears.
type gearbox case conversion. For 45 22A550 WASHER, thrust, 0.212-0.213" 1 For 22A89, 22A583, 22A261 or
2A3719 or 22A425 shafts. (5.38-5.41mm) 22A415 3rd speed gears.
AAU1365 BEARING, 3rd motion shaft 1 For 22G70 or 22G392 3rd motion shafts . 22A536 WASHER, thrust, 0.214-0.215" 1 For 22A89, 22A583, 22A261 or
21 2A3713 RING, spring, bearing retaining 1 Fit to 2A3712 bearing. (5.43-5.46mm) 22A415 3rd speed gears.
ADU4992 RING, spring, bearing retaining 1 Fit to AAU1365 bearing. 22A537 WASHER, thrust, 0.216-0.217" 1 For 22A89, 22A583, 22A261 or
22 2A3716 RETAINER, 3rd motion shaft bearing 1 For 2A3712 3rd motion shaft bearing. (5.48-5.51mm) 22A415 3rd speed gears.
22A522 RETAINER, 3rd motion shaft bearing 1 For AAU1365 3rd motion shaft bearing. 22A538 WASHER, thrust, 0.218-0.219" 1 For 22A89, 22A583, 22A261 or
23 SH505081 SCREW, retainer to gearbox case 4 (5.53-5.56mm) 22A415 3rd speed gears.
24 DAM2377 LOCK TAB, screw 2 46 22A495 PEG, thrust washer 1 For 22A89, 22A583, 22A261 or
25 2A3714 SHIM, retainer A/R 0.003" (0.076mm) 22A415 3rd speed gears.
2A3715 SHIM, retainer A/R 0.010" (0.254mm) 47 22A528 SPRING, thrust washer 1 For 22A89, 22A583, 22A261 or
22A415 3rd speed gears.
1st/2nd Synchroniser 48 22G149 BEARING, needle roller, 3rd speed gear 26 For 22G195, 22A981 or 22A983
26 22A433 GEAR ASS’Y, 1st/2nd synchroniser 1 1959-62; 848 models, Cone Synchro. 3rd speed gears.
1961-62; 997 Cooper, Cone Synchro. 49 22G196 COLLAR, locking, 3rd speed gear 1 For 22G195, 22A981 or 22A983
22G440 GEAR ASS’Y, 1st/2nd synchroniser 1 1962-64; 848 models, A Type gears . 3rd speed gears.
1962-63; 997 Cooper, A Type gears. 50 22A495 PEG, 3rd speed gear locking collar 1 For 22G195, 22A981 or 22A983
1963; 997 Cooper, A Type gears . 3rd speed gears.
22A1021 GEAR ASS’Y, 1st/2nd synchroniser 1 1963-64; 997/998 Cooper, 1071 51 22G154 SPRING, 3rd speed gear locking collar 1 For 22G195, 22A981 or 22A983
Cooper S , A Type gears with B Type 3rd speed gears.
1st/2nd synchroniser and reverse.
1964-68; 848 and 998 (not Cooper) 3rd/4th Synchroniser
models, B Type gears. 52 22A26 GEAR ASS’Y, 3rd/4th synchroniser 1 1959-62; 848 models, Cone Synchro.
1964-68; 998 Cooper, 970/1071/1275 1961-62; 997 Cooper, Cone Synchro.
Cooper S, B Type gears . 22G97 GEAR ASS’Y, 3rd/4th synchroniser 1 1962-64; 848 models, A Type gears.
The 1st speed outer ring for the 22A1021 gear assembly is sometimes available separately as the repair 1962-63; 997 Cooper, A Type gears .
part 22A1021A. However its compatibility with an old 2nd speed synchro hub cannot be completely 22G410 GEAR ASS’Y, 3rd/4th synchroniser 1 1963; 997 Cooper, A Type gears .
guaranteed as the outer ring and hub were designed to be supplied as a matched pair. 1963-64; 997/998 Cooper, 1071
Cooper S , A Type gears with B Type
27 BLS107 BALL, synchroniser 6/3 Qty. 6 used on very ear ly Cone Synchro. 1st/2nd synchroniser and reverse.
28 22A367 SPRING , synchroniser 6/3 Qty. 6 used on very ear ly Cone Synchro. 1964-68; 848 and 998 (not Cooper)
29 22G89 PLUNGER, 2nd speed synchroniser 1 models, B Type gears .
1964-68; 998 Cooper, 970/1071/1275
2nd Gear Cooper S, B Type gears .
30 22A90 GEAR, 2nd speed, with synchro cone, 1 1959-62; 848 models, Cone Synchro. 53 BLS107 BALL, synchroniser 6/3 Qty. 6 used on Cone Synchro.
28 teeth 1961-62; 997 Cooper, Cone Synchro. 54 22A367 SPRING, synchroniser 6/3 Qty. 6 used on Cone Synchro.
22A582 GEAR, 2nd speed, 28 teeth 1 1962-64; 848 models, A Type gears .
1962-63; 997 Cooper, A Type gears. Final Drive Pinion
22G194 GEAR, 2nd speed, 28 teeth 1 1963; 997 Cooper, A Type gears . 55 22G99 PINION, final drive , 15 teeth, 4.333:1 ratio 1 With 65 tooth 22G443 final drive gear.
1963-64; 997/998 Cooper, 1071 22G99 PINION, final drive , 15 teeth, 4.267:1 ratio 1 With 64 tooth 22G370 final drive gear.
Cooper S , A Type gears with B Type 22G99 PINION, final drive , 15 teeth, 4.133:1 ratio 1 With 62 tooth 22G101 final drive gear.
1st/2nd synchroniser and reverse. 22G338 PINION, final drive , 16 teeth, 3.938:1 ratio 1 With 63 tooth 22G340 final drive gear.
22A980 GEAR, 2nd speed, 28 teeth 1 1964-68; 848 and 998 (not Cooper) 22A399 PINION, final drive , 17 teeth, 3.765:1 ratio 1 With 64 tooth 22A401 final drive gear.
models, B Type gears. 22A399 PINION, final drive , 17 teeth, 3.647:1 ratio 1 With 62 tooth 22G940 final drive gear.
1964-68; 998 Cooper, 970/1071/1275 22A413 PINION, final drive , 18 teeth, 3.444:1 ratio 1 With 62 tooth 22A411 final drive gear.
Cooper S, B Type gears . 56 2A3575 NUT, pinion retaining 1 For 2A3719 3rd motion shaft.
31 2A3693 CONE, synchronising 1 For 22A90 2nd speed gear. 57 2A3576 LOCK TAB, pinion nut 1 For 2A3719 3rd motion shaft.
32 22G2033 RING, baulk 1 For 22A582, 22G194 or 22A980 gears. 58 DAM7485 NUT, pinion retaining 1 For all other 3rd motion shafts .
33 2A3042 WASHER, thrust, 2nd speed gear 1 1959-64; all Cone Synchro and A Type 59 DAM6140 LOCK TAB, pinion nut 1 For all other 3rd motion shafts .
2nd speed gears.

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