Manual gearbox - 3 synchromesh internal components

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LAYSHAFT-3 SYNCHRO GEARBOX
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SPRING-SYNCHRONISER-3 SYNCHRO.
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3 Synchro Internal Gearbox
1959-68
The 3 synchromesh gearbox was fitted to all Minis between 1959 and 1968.  It is so called because synchromesh is only available on 2nd, 3rd and 4th 
gears, 1st gear being of the 'crash' engagement type (probably the most common fault on this gearbox is jumping out of first gear, followed closely by
laygear bearing and layshaft failure).  A proper first speed gear was inserted in the gearbox in 1968, at last receiving the great benefit of synchromesh 
engagement; this gearbox is termed 4 synchro and its internal components are covered in the next section of the catalogue.
         
If you've not been inside a 3 synchro Mini gearbox before or you can't remember when you last did, please read these notes carefully - they could save 
you a lot of heartache.  The gearbox internal components were revised several times, with the changes being introduced at broadly the same times 
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... we'll explain those as best we can as we go along).  
         
The first 3 synchro gearbox fitted to the Mini is known as the 'cone synchromesh' gearbox, because of 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 
were changed to quieten the baulk ring gearbox.  The modified gears were known as B Type gears, the 1962-63 gears retrospectively becoming known 
as A Type gears.  So there you have it: 1959-62 Cone Synchromesh gearbox, 1962-63/64 A Type Gears gearbox and 1963/64-68 B Type Gears gearbox 
(plus, in 1963-64, an A Type gearbox with B Type 1st/2nd synchroniser and reverse idler...!).     
         
Gearbox Identification
Between the three gearbox types, many, many components are not interchangeable.  This makes it especially important to identify your gearbox before 
ordering parts, which can be difficult, particularly when trying to work out whether you have A or B Type gears.  Originally, gearbox cases were stamped 
with a part number denoting the gear types within and the model application; however 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.    
         
The only surefire way to identify the gearbox nowadays is to inspect the internals with a small check list to hand, paying particular attention to: 
(i) the presence of synchro cones or baulk rings (Cone Synchro box for the first, A Type and B Type boxes for the second); 
(ii) If baulk rings are present, do the second and third gears run on bushes - the bush interlocking ring being visible between the two gears on the 
mainshaft gear cluster - or do they run on bearings (A Type gears except 1963 Cooper 997 for bushes, A Type gears 1963 Cooper 997, hybrid A/B Type 
and B Type gears for bearings).
(iii) The number of teeth on the laygear (13/19/24/28 for non Cooper, 13/19/23/26 for Cooper, other combinations for Special Tuning options)
(iv) Are the laygear bearing circlips on the outside or inside of the bearings (Cone Synchro and A Type gears except 1963 Cooper 997 for outside circlips, 
A Type gears 1963 Cooper 997, hybrid A/B Type and B Type gears for inside circlips).
         
The laygear should tell you which combination of gears you have... 'should' because the laygear part number was traditionally stamped on the component
between the largest and second largest gears, but some reproduction gears (mostly in the case of 22G1100) don't have this.  Identifying your laygear 
allows you to work out what other gears have been used in the gearbox, since they were designed to go together as matched gear sets and are usually 
not interchangeable.  For this reason, all the other major components in this section use the application remarks shown alongside the laygears 
- even if it's a bit long-winded sometimes, it positively matches the sets together.  
         
Be careful with 848 and 997 Cooper A Type gears 'boxes, though - some have been converted from cone synchro to baulk ring A Type gears, retaining
the original laygear; some other components used in cone to baulk ring converted gearboxes are unique and most are not listed here (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.  
If you find 22G83 or 22G714 on your laygear, you have an Austin/Morris 1100 or 1300 gearbox, not a Mini one.  
         
Parts Availability
Unfortunately, parts 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.  The B Type gears do, however, benefit marginally from the fact that the MG Midget continued to use versions of 
them until 1974, which slightly increases parts demand and availability.  Many parts listed in this section are therefore shown only as a matter of 
reference.  
         
We will always do our utmost to help you seek out parts for your gearbox, but by rule of thumb the 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 condition, gearbox instead.  You have been warned...  
         
Close Ratio and Straight Cut Gears
Close ratio straight cut gear sets are available to build into gearboxes with B Type Gears components, as a special order.  Please contact us for
details.  Similarly, please contact us if you have factory-optional helical close ratio, straight cut close ratio or straight cut standard ratio gears in your
gearbox and you require replacement parts.
         
Reverse Idler Gear
Ill. No. Part No. Description Qty. Rqd. Remarks
1 22A377 REVERSE IDLER, with bush, 18 teeth 1 1959-64; 848 models, Cone Synchro and A Type gears.
        1961-62; 997 Cooper, Cone Synchro.
        1962-63; 997 Cooper, A Type gears.
        1963; 997 Cooper, A Type gears. 
  22G202 REVERSE IDLER, with bush, 18 teeth 1 1963-64; 997/998 Cooper, 1071 Cooper S, A Type gears with
        B Type 1st/2nd synchroniser and reverse gears.
        1964-68; 848 and 998 (not Cooper) models, B Type gears.
        1964-68; 998 Cooper, 970/1071/1275 Cooper S, B Type gears.
2 2A3475 BUSH, reverse idler 1  
3 DAM8038 SHAFT, reverse idler 1  
         
Laygear
Ill. No. Part No. Description Qty. Rqd. Remarks
4 22A381 LAYGEAR, 13/19/24/28 teeth 1 1959-64; 848 models, Cone Synchro and A Type gears.
  22A350 LAYGEAR, 13/19/23/26 teeth 1 1961-62; 997 Cooper, Cone Synchro.
  22G76 LAYGEAR, 13/19/23/26 teeth 1 1962-63; 997 Cooper, A Type gears.
  22G197 LAYGEAR, 13/19/23/26 teeth 1 1963; 997 Cooper, A Type gears. 
  22G204 LAYGEAR, 13/19/23/26 teeth 1 1963-64; 997/998 Cooper, 1071 Cooper S, A Type gears with B Type 1st/2nd synchroniser and reverse gears.
  22G231 LAYGEAR, 13/19/24/28 teeth 1 1964-68; 848 and 998 (not Cooper) models, B Type gears.
  22G1100 LAYGEAR, 13/19/23/26 teeth 1 1964-68; 998 Cooper, 970/1071/1275 Cooper S, B Type gears.
5 22A1371 LAYSHAFT 1  
6 2A3581 PLATE, locating reverse idler shaft and layshaft 1  
7 88G396 BEARING, needle roller, laygear 2  
8 22G277 DISTANCE PIECE, bearing 1  
9 22G278 CIRCLIP, bearing retaining 2  
10 88G325 WASHER, thrust, large 1 0.123-0.124" (3.12-3.14mm).
  88G326 WASHER, thrust, large 1 0.125-0.126" (3.17-3.20mm).
  88G327 WASHER, thrust, large 1 0.127-0.128" (3.22-3.25mm).
  88G328 WASHER, thrust, large 1 0.130-0.131" (3.30-3.32mm).
11 88G324 WASHER, thrust, small 1  
         
1st Motion Shaft
Ill. No. Part No. Description Qty. Rqd. Remarks
12 22A88 SHAFT, 1st motion, with synchro cone, 19 teeth 1 1959-62; 848 models, Cone Synchro.
  22A588 SHAFT, 1st motion, 19 teeth 1 1962-64; 848 models, A Type gears.
  22A257 SHAFT, 1st motion, with synchro cone, 20 teeth 1 1961-62; 997 Cooper, Cone Synchro.
  22A416 SHAFT, 1st motion, 20 teeth 1 1962-63; 997 Cooper, A Type gears.
  22A592 SHAFT, 1st motion, 20 teeth 1 1963; 997 Cooper, A Type gears. 
        1963-64; 997/998 Cooper, 1071 Cooper S, A Type gears with B Type 1st/2nd synchroniser and reverse gears.
  22A979 SHAFT, 1st motion, 19 teeth 1 1964-68; 848 and 998 (not Cooper) models, B Type gears.
  22A982 SHAFT, 1st motion, 20 teeth 1 1964-68; 998 Cooper, 970/1071/1275 Cooper S, B Type gears.
13 2A3693 CONE, synchronising 1 Fit to 22A88 and 22A257 1st motion shafts.
Note that synchro cones have to be shrunk onto their respective gears and then finally machined - not a task for most home-based Mini restorers.
         
Ill. No. Part No. Description Qty. Rqd. Remarks
14 22G2033 RING, baulk 1 Fit to 22A588, 22A416, 22A592, 22A979 and 22A982 1st motion shafts.
15 22G314 BEARING, 1st to 3rd motion shaft 1 Fit to 22A88, 22A588, 22A257 and 22A416 1st motion shafts. 
  CHM172 BEARING, needle roller, 1st to 3rd motion shaft 1 Fit to 22A592, 22A979 and 22A982 1st motion shafts.
16 2A3709 BEARING, 1st motion shaft  1 In gearbox case.
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)
For the 1st motion shaft bearing supporting the nose of the shaft in the flywheel housing, please see the 'Flywheel Housing and Clutch Cover' section.
         
3rd Motion Shaft
Ill. No. Part No. Description Qty. Rqd. Remarks
18 2A3719 SHAFT, 3rd motion 1 1959-61; 848 models, Cone Synchro.
        1961; 997 Cooper, Cone Synchro.
  22A425 SHAFT, 3rd motion 1 1961-62; 848 models, Cone Synchro.
        1961-62; 997 Cooper, Cone Synchro.
  22A421 SHAFT, 3rd motion 1 1959-62; Cone Synchro to baulk ring synchro conversion item.
  22G70 SHAFT, 3rd motion 1 1962-64; 848 models, A Type gears.
        1962-63; 997 Cooper, A Type gears.
        1963; 997 Cooper, A Type gears. 
        1963-64; 997/998 Cooper, 1071 Cooper S, A Type gears with
        B Type 1st/2nd synchroniser and reverse gears.
  22G392 SHAFT, 3rd motion 1 1964-68; 848 and 998 (not Cooper) models, B Type gears.
        1964-68; 998 Cooper, 970/1071/1275 Cooper S, B Type gears.
19 22A422 WASHER, spacing  1 1959-62; Cone Synchro to baulk ring synchro conversion item.
20 2A3712 BEARING, 3rd motion shaft 1 Fit to 2A3719, 22A425 and 22A421 3rd motion shafts.
  22A575 BEARING, 3rd motion shaft 1 1959-62; for Cone Synchro to baulk ring type gearbox case conversion.  Fit to 2A3719 and 22A425 3rd motion shafts. 
  AAU1365 BEARING, 3rd motion shaft 1 Fit to 22G70 and 22G392 3rd motion shafts.
21 2A3713 RING, spring, bearing retaining 1 Fit to 2A3712 bearing.
  ADU4992 RING, spring, bearing retaining 1 Fit to AAU1365 bearing.
22 2A3716 RETAINER, 3rd motion shaft bearing 1 For 2A3712 3rd motion shaft bearing.
  22A522 RETAINER, 3rd motion shaft bearing 1 For AAU1365 3rd motion shaft bearing.
23 SH505081 SCREW, coarse thread, retainer to gearbox case 4  
24 DAM2377 LOCK TAB, screw 2  
25 2A3714 SHIM, retainer A/R 0.003" (0.076mm)
  2A3715 SHIM, retainer A/R 0.010" (0.254mm)
         
1st/2nd Synchroniser
Ill. No. Part No. Description Qty. Rqd. Remarks
26 22A433 GEAR ASS'Y, 1st/2nd synchroniser 1 1959-62; 848 models, Cone Synchro.
        1961-62; 997 Cooper, Cone Synchro.
  22G440 GEAR ASS'Y, 1st/2nd synchroniser 1 1962-64; 848 models, A Type gears.
        1962-63; 997 Cooper, A Type gears.
        1963; 997 Cooper, A Type gears. 
  22A1021 GEAR ASS'Y, 1st/2nd synchroniser 1 1963-64; 997/998 Cooper, 1071 Cooper S, A Type gears with B Type 1st/2nd synchroniser and reverse gears.
        1964-68; 848 and 998 (not Cooper) models, B Type gears.
        1964-68; 998 Cooper, 970/1071/1275 Cooper S, B Type gears.
The 1st speed outer ring for the 22A1021 gear assembly is sometimes available separately as the repair part 22A1021A.  However its compatibility with an old 2nd speed synchro hub cannot be completely guaranteed as the outer ring and hub were designed to be supplied as a matched pair.
         
Ill. No. Part No. Description Qty. Rqd. Remarks
27 BLS107 BALL, synchroniser 6/3 Qty. 6 used on very early Cone Synchro.
28 22A367 SPRING, synchroniser 6/3 Qty. 6 used on very early Cone Synchro.
29 22G89 PLUNGER, 2nd speed synchroniser 1  
         
2nd Gear
Ill. No. Part No. Description Qty. Rqd. Remarks
30 22A90 GEAR, 2nd speed, with synchro cone, 28 teeth 1 1959-62; 848 models, Cone Synchro.
        1961-62; 997 Cooper, Cone Synchro.
  22A582 GEAR, 2nd speed, 28 teeth 1 1962-64; 848 models, A Type gears.
        1962-63; 997 Cooper, A Type gears.
  22G194 GEAR, 2nd speed, 28 teeth 1 1963; 997 Cooper, A Type gears. 
        1963-64; 997/998 Cooper, 1071 Cooper S, A Type gears with
        B Type 1st/2nd synchroniser and reverse gears.
  22A980 GEAR, 2nd speed, 28 teeth 1 1964-68; 848 and 998 (not Cooper) models, B Type gears.
        1964-68; 998 Cooper, 970/1071/1275 Cooper S, B Type gears.
31 2A3693 CONE, synchronising 1 Fit to 22A90 2nd speed gear.
32 22G2033 RING, baulk 1 Fit to 22A582, 22G194 and 22A980 2nd speed gears.
33 2A3042 WASHER, thrust, 2nd speed gear 1 1959-64; all Cone Synchro and A Type 2nd speed gears.
34 2A3298 BUSH, 2nd speed gear 1 Fit to 22A90 and 22A582 2nd speed gears.
35 22G374 RING, interlocking, 2nd and 3rd speed gear bushes 1 Fit to 22A90 and 22A582 2nd speed gears.
36 22G186 COLLAR, locking, 2nd speed gear 1 Fit to 22G194 and 22A980 2nd speed gears.
37 22G149 BEARING, needle roller, 2nd speed gear 26 Fit to 22G194 and 22A980 2nd speed gears.
38 22G157 WASHER, 2nd speed gear locking collar 2 Fit to 22G194 and 22A980 2nd speed gears.
39 22A495 PEG, 2nd speed gear locking collar 1 Fit to 22G194 and 22A980 2nd speed gears.
40 22G154 SPRING, 2nd speed gear locking collar 1 Fit to 22G194 and 22A980 2nd speed gears.
         
3rd Gear
Ill. No. Part No. Description Qty. Rqd. Remarks
41 22A89 GEAR, 3rd speed, with synchro cone, 23 teeth 1 1959-62; 848 models, Cone Synchro.
  22A583 GEAR, 3rd speed, 23 teeth 1 1962-64; 848 models, A Type gears.
  22A261 GEAR, 3rd speed, with synchro cone, 24 teeth 1 1961-62; 997 Cooper, Cone Synchro.
  22A415 GEAR, 3rd speed, 24 teeth 1 1962-63; 997 Cooper, A Type gears.
  22G195 GEAR, 3rd speed, 24 teeth 1 1963; 997 Cooper, A Type gears. 
        1963-64; 997/998 Cooper, 1071 Cooper S, A Type gears with B Type 1st/2nd synchroniser and reverse gears.
  22A981 GEAR, 3rd speed, 23 teeth 1 1964-68; 848 and 998 (not Cooper) models, B Type gears.
  22A983 GEAR, 3rd speed, 24 teeth 1 1964-68; 998 Cooper, 970/1071/1275 Cooper S, B Type gears.
42 2A3693 CONE, synchronising 1 Fit to 22A89 and 22A261 2nd speed gears.
43 22G2033 RING, baulk 1 Fit to 22A583, 22A415, 22G195, 22A981 and 22A983 2nd speed gears.
44 2A3290 BUSH, 3rd speed gear 1 Fit to 22A89, 22A583, 22A261 and 22A415 3rd speed gears.
45 22A550 WASHER, thrust, 0.212-0.213" (5.38-5.41mm) 1 Fit to 22A89, 22A583, 22A261 and 22A415 3rd speed gears.
  22A536 WASHER, thrust, 0.214-0.215" (5.43-5.46mm) 1 Fit to 22A89, 22A583, 22A261 and 22A415 3rd speed gears.
  22A537 WASHER, thrust, 0.216-0.217" (5.48-5.51mm) 1 Fit to 22A89, 22A583, 22A261 and 22A415 3rd speed gears.
  22A538 WASHER, thrust, 0.218-0.219" (5.53-5.56mm) 1 Fit to 22A89, 22A583, 22A261 and 22A415 3rd speed gears.
46 22A495 PEG, thrust washer 1 Fit to 22A89, 22A583, 22A261 and 22A415 3rd speed gears.
47 22A528 SPRING, thrust washer 1 Fit to 22A89, 22A583, 22A261 and 22A415 3rd speed gears.
48 22G149 BEARING, needle roller, 3rd speed gear 26 Fit to 22G195, 22A981 and 22A983 3rd speed gears.
49 22G196 Collar, locking, 3rd speed gear 1 Fit to 22G195, 22A981 and 22A983 3rd speed gears.
50 22A495 PEG, 3rd speed gear locking collar 1 Fit to 22G195, 22A981 and 22A983 3rd speed gears.
51 22G154 SPRING, 3rd speed gear locking collar 1 Fit to 22G195, 22A981 and 22A983 3rd speed gears.
         
3rd/4th Synchroniser
Ill. No. Part No. Description Qty. Rqd. Remarks
52 22A26  GEAR ASS'Y, 3rd/4th synchroniser 1 1959-62; 848 models, Cone Synchro.
        1961-62; 997 Cooper, Cone Synchro.
  22G97 GEAR ASS'Y, 3rd/4th synchroniser 1 1962-64; 848 models, A Type gears.
        1962-63; 997 Cooper, A Type gears.
  22G410 GEAR ASS'Y, 3rd/4th synchroniser 1 1963; 997 Cooper, A Type gears. 
        1963-64; 997/998 Cooper, 1071 Cooper S, A Type gears with B Type 1st/2nd synchroniser and reverse gears.
        1964-68; 848 and 998 (not Cooper) models, B Type gears.
        1964-68; 998 Cooper, 970/1071/1275 Cooper S, B Type gears.
53 BLS107 BALL, synchroniser 6/3 Qty. 6 used on Cone Synchro.
54 22A367 SPRING, synchroniser 6/3 Qty. 6 used on Cone Synchro.
         
Final Drive Pinion
Ill. No. Part No. Description Qty. Rqd. Remarks
55 22G99 PINION, final drive, 15 teeth 1 4.333:1 ratio (with 65 tooth 22G443 final drive gear). 
  22G99 PINION, final drive, 15 teeth 1 4.267:1 ratio (with 64 tooth 22G370 final drive gear). 
  22G99 PINION, final drive, 15 teeth 1 4.133:1 ratio (with 62 tooth 22G101 final drive gear). 
  22G338 PINION, final drive, 16 teeth 1 3.938:1 ratio (with 63 tooth 22G340 final drive gear). 
  22A399 PINION, final drive, 17 teeth 1 3.765:1 ratio (with 64 tooth 22A401 final drive gear). 
  22A399 PINION, final drive, 17 teeth 1 3.647:1 ratio (with 62 tooth 22G940 final drive gear). 
  22A413 PINION, final drive, 18 teeth 1 3.444:1 ratio (with 62 tooth 22A411 final drive gear). 
56 2A3575 NUT, pinion retaining 1 Fit to 2A3719 3rd motion shaft.
57 2A3576 LOCK TAB, pinion nut 1 Fit to 2A3719 3rd motion shaft.
58 22G48 NUT, pinion retaining 1 Fit to 22A425, 22G70 and 22G392 3rd motion shafts.
59 DAM6140 LOCK TAB, pinion nut 1 Fit to 22A425, 22G70 and 22G392 3rd motion shafts.
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