Manual gearbox - 4 synchromesh internal components

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4 Synchro Internal Gearbox    
1968 On      
Fortunately for the majority of our customers, 4 synchro gearboxes are much easier to identify and classify than their 3 synchro predecessors (parts 
availability is considerably better, too, but not brilliant sometimes).  The two main change points are 1979, when the gear shafts and several of the 
bearings were modified, and 1982 - approximately - when A Plus gears were introduced.  
         
A Plus gears were introduced on the Mini round about 1982 (at different times on different models...), and have a sharper tooth angle and different pitch 
making them quieter than, but definitely not interchangeable with, the earlier gears.  Looking in the gearbox, A Plus gears can be identified by the 
presence of a circumferential groove in the centre of the teeth, and the final drive pinion on the gearbox mainshaft is machined flush on both sides.    
         
The following summaries should help with the identification of your gearbox and give you points to watch out for when ordering parts:
         
1968-73 Saloon and Estate, 1968-75 Van and Pick Up    
Pre-A Plus gears.  Direct/remote gearchange type reverse gear and mainshaft bearing retainer (four screw fitting).  9/16" dia. nose on 3rd motion shaft, 
two step layshaft, laygear takes two large bearings and one small bearing.  Different ratios for 1275 models.
         
1973-79 Saloon and Estate, 1975-79 Van and Pick Up    
Pre-A Plus gears.  Rod gearchange type reverse gear and mainshaft bearing retainer (4 screw fitting).  9/16" dia. nose on 3rd motion shaft, two step 
layshaft, laygear takes two large bearings and one small bearing.  Different ratios for 1275 models.
         
1979-82       
Pre-A Plus gears (except for final drive pinion on 3.444:1 ratio models, which became A Plus in 1979).  Rod gearchange type reverse gear and mainshaft 
bearing retainer (4 screw fitting).  11/16" dia. nose on 3rd motion shaft, three step layshaft, laygear takes one large and one small bearing. Idler and 1st 
motion shaft drive gear ratios revised, idler gear bearings in gearbox case revised (diameter change).  Different ratios for 1275 models.
         
1982 on      
A Plus gears.  Rod gearchange type reverse gear and mainshaft bearing retainer (4 screw fitting reducing to 3 screw fitting in 1984).  11/16" dia. nose  
on 3rd motion shaft, three step layshaft, laygear takes one large and one small bearing.  Different ratios for French 1275 models in the 1990s.
         
Close ratio and straight cut close ratio gear sets are available for 4 synchro pre-A Plus and A Plus gearboxes, as a special order.  Please contact
us for details.  Similarly, please contact us if you already have factory-optional helical close ratio or straight cut close ratio gears in your gearbox and
you require replacement parts.    
         
Reverse Idler Gear    
Ill. No. Part No. Description Qty. Rqd. Remarks
1 22G1034 REVERSE IDLER, 17/18 teeth, direct/remote gearchange type 1 1968-73, Saloons and Estates; 1968-75, Vans and Pick Ups.
  22G1832 REVERSE IDLER, 17/18 teeth, rod gearchange type 1 1973-79, Saloons and Estates; 1976-79, Vans and Pick Ups.
  TUB10020 REVERSE IDLER, 17/18 teeth, rod gearchange type 1 1979 on.
2 TUJ10001 BUSH, reverse idler 1  
3 DAM8038 SHAFT, reverse idler 1  
         
Laygear      
Ill. No. Part No. Description Qty. Rqd. Remarks
4 22G927 LAYGEAR, 15/20/25/29 teeth, for two step layshaft  1 1968-79; not 1275 models.
  22G1040 LAYGEAR, 15/20/25/29 teeth, for two step layshaft  1 1968-79; 1275 models.
5 DAM3169 LAYGEAR, 15/20/25/29 teeth, for three step layshaft  1 1979-82; not 1275 models.
  DAM3168 LAYGEAR, 15/20/25/29 teeth, for three step layshaft  1 1979-80; 1275 models.
  DAM4931 LAYGEAR, 15/21/26/30 teeth, A Plus type, for three step layshaft  1 1982 on; not 1990-96, 1275 (France).  
  DAM6238 LAYGEAR, 15/21/27/31 teeth, A Plus type, for three step layshaft  1 1990-96, 1275 (France).  
6 22G931 LAYSHAFT, two step type 1 Fit to 22G927 and 22G1040 laygears.
7 DAM3187 LAYSHAFT, three step type 1 Fit to DAM3169, DAM3168, DAM4931 and DAM6238 laygears.
8 2A3581 PLATE, locating reverse idler shaft and layshaft 1  
9 CHM141 BEARING, needle roller, laygear, large 2/1 Qty. 2 fitted to 22G927 and 22G1040 laygears only.
10 88G396 BEARING, needle roller, laygear, small 1 Fit to 22G927 and 22G1040 laygears.
11 13H9513 BEARING, needle roller, laygear, small 1 Fit to DAM3169, DAM3168, DAM4931 and DAM6238 laygears.
12 22G856 WASHER, thrust, small, 0.123-0.124" (3.12-3.14mm) 1 Fit to 22G927 and 22G1040 laygears.
  22G857 WASHER, thrust, small, 0.125-0.126" (3.17-3.20mm) 1 Fit to 22G927 and 22G1040 laygears.
  22G858 WASHER, thrust, small, 0.127-0.128" (3.22-3.25mm) 1 Fit to 22G927 and 22G1040 laygears.
  22G859 WASHER, thrust, small, 0.130-0.131" (3.30-3.32mm) 1 Fit to 22G927 and 22G1040 laygears.
13 DAM3180 WASHER, thrust, small, 0.121-0.123" (3.07-3.12mm) 1 Fit to DAM3169, DAM3168, DAM4931 and DAM6238 laygears.
  DAM3181 WASHER, thrust, small, 0.124-0.126" (3.15-3.20mm) 1 Fit to DAM3169, DAM3168, DAM4931 and DAM6238 laygears.
  DAM3182 WASHER, thrust, small, 0.127-0.129" (3.22-3.27mm) 1 Fit to DAM3169, DAM3168, DAM4931 and DAM6238 laygears.
  DAM3183 WASHER, thrust, small, 0.130-0.132" (3.30-3.35mm) 1 Fit to DAM3169, DAM3168, DAM4931 and DAM6238 laygears.
14 22G860 WASHER, thrust, large 1  
         
1st Motion Shaft    
Ill. No. Part No. Description Qty. Rqd. Remarks
15 22G1093 SHAFT, 1st motion, 17 teeth 1 1968-79; not 1275 models.
  22G1371 SHAFT, 1st motion, 18 teeth 1 1968-79; 1275 models.
  DAM3092 SHAFT, 1st motion, 17 teeth 1 1979-82; not 1275 models.
  DAM3167 SHAFT, 1st motion, 18 teeth 1 1979-80; 1275 models.
  DAM4930 SHAFT, 1st motion, 17 teeth, A Plus type 1 1982 on; not 1990-96, 1275 (France).  
  DAM6242 SHAFT, 1st motion, 16 teeth, A Plus type 1 1990-96, 1275 (France).  
16 22G2033 RING, baulk 1  
17 CHM172 BEARING, 1st to 3rd motion shaft, 9/16" int. dia. 1 Fit to 22G1093 and 22G1371 1st motion shafts.
  13H9513 BEARING, 1st to 3rd motion shaft, 11/16" int. dia. 1 Fit to DAM3092, DAM3167, DAM4930 and DAM6242 1st motion shafts.
18 ADU7619 BEARING, 1st motion shaft  1 In gearbox case.
19 22G850 CIRCLIP, bearing retaining 1 0.094-0.096" (2.39-2.44mm)
  22G851 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
20 22G833 SHAFT, 3rd motion, 9/16" nose dia. 1 1968-79.
  DAM7484 SHAFT, 3rd motion, 11/16" nose dia. 1 1979 on.
21 AAU1365 BEARING, 3rd motion shaft 1  
22 ADU4992 RING, spring, bearing retaining 1  
23 22A522 RETAINER, 3rd motion shaft bearing, 4 screw fixing, direct/remote gearchange type 1 1968-73, Saloons and Estates; 1968-75, Vans and Pick Ups.
  DAM1756 RETAINER, 3rd motion shaft bearing, 4 screw fixing, rod gearchange type 1 1973-84, Saloons and Estates; 1976-84, Vans and Pick Ups.
24 DAM5996 RETAINER, 3rd motion shaft bearing, 3 screw fixing, rod gearchange type 1 1984 on.
25 SH505071 SCREW, coarse thread, retainer to gearbox case 4/3 Qty. 4 fitted to 22A522 and DAM1756 retainers only.
26 DAM2377 LOCK TAB, screw 2/1 Qty. 2 fitted to 22A522 and DAM1756 retainers only.
27 DAM6047 LOCK TAB, screw 1 Fitted to DAM5996 retainer.
28 2A3714 SHIM, retainer A/R 0.003" (0.076mm)
  2A3715 SHIM, retainer A/R 0.010" (0.254mm)
         
1st Gear      
Ill. No. Part No. Description Qty. Rqd. Remarks
29 22G1096 GEAR, 1st speed, 31 teeth 1  
30 22G2033 RING, baulk 1  
31 AAU1815 BEARING, needle roller, 1st speed gear 1  
32 22G837 JOURNAL, 1st speed gear 1  
         
1st/2nd Synchroniser    
Ill. No. Part No. Description Qty. Rqd. Remarks
33 DAM7455 GEAR ASS'Y, 1st/2nd synchroniser 1  
34 BLS107 BALL, synchroniser 3  
35 22G2262 SPRING, synchroniser 3  
         
2nd Gear      
Ill. No. Part No. Description Qty. Rqd. Remarks
36 22G1094 GEAR, 2nd speed, 26 teeth 1 1968-82.
  DAM4932 GEAR, 2nd speed, 26 teeth, A Plus type 1 1982 on; not 1990-96, 1275 (France). 
  DAM6240 GEAR, 2nd speed, 25 teeth, A Plus type 1 1990-96, 1275 (France). 
37 22G2033 RING, baulk 1  
38 AAU1816 BEARING, needle roller, 2nd speed gear 1  
39 22G839 WASHER, thrust, 2nd speed gear 1  
40 22G843 PEG, 2nd speed gear  2  
41 22G154 SPRING, 2nd speed gear  1  
         
3rd Gear      
Ill. No. Part No. Description Qty. Rqd. Remarks
42 22G1095 GEAR, 3rd speed, 21 teeth 1 1968-82.
  DAM4933 GEAR, 3rd speed, 21 teeth, A Plus type 1 1982 on; not 1990-96, 1275 (France).  
  DAM6241 GEAR, 3rd speed, 20 teeth, A Plus type 1 1990-96, 1275 (France).  
43 22G2033 RING, baulk 1  
44 AAU1816 BEARING, needle roller, 3rd speed gear 1  
45 22G947 WASHER, thrust, 3rd speed gear 1  
46 22G843 PEG, 3rd speed gear  1  
47 22G154 SPRING, 3rd speed gear  1  
         
3rd/4th Synchroniser    
Ill. No. Part No. Description Qty. Rqd. Remarks
48 DAM7456 GEAR ASS'Y, 3rd/4th synchroniser 1  
49 BLS107 BALL, synchroniser 3  
50 22G2262 SPRING, synchroniser 3  
         
Final Drive Pinion    
Ill. No. Part No. Description Qty. Rqd. Remarks
51 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). 
  DAM3647 PINION, final drive, 15 teeth, A Plus type 1 4.333:1 ratio (with 65 tooth DAM3645 final drive gear).
  DAM3218 PINION, final drive, 16 teeth, A Plus type 1 3.938:1 ratio (with 63 tooth DAM3216 final drive gear).
  DAM4131 PINION, final drive, 17 teeth, A Plus type 1 3.765:1 ratio (with 64 tooth DAM4779 final drive gear).
  DAM4131 PINION, final drive, 17 teeth, A Plus type 1 3.647:1 ratio (with 62 tooth DAM4162 final drive gear).
  DAM2679 PINION, final drive, 18 teeth, A Plus type 1 3.444:1 ratio (with 62 tooth DAM2677 final drive gear).
  DAM2808 PINION, final drive, 19 teeth, A Plus type 1 3.211:1 ratio (with 61 tooth DAM2806 final drive gear).
  DAM2808 PINION, final drive, 19 teeth, A Plus type 1 3.105:1 ratio (with 59 tooth DAM6327 final drive gear).
  DAM5927 PINION, final drive, 20 teeth, A Plus type 1 2.950:1 ratio (with 59 tooth DAM5925 final drive gear).
  TCC10001 PINION, final drive, 21 teeth, A Plus type 1 2.762:1 ratio (with 58 tooth TCB10004 final drive gear).
52 22G48 NUT, pinion retaining 1 1968-82.
  DAM7485 NUT, pinion retaining, A Plus type 1 1982 on.
53 DAM6140 LOCK TAB, pinion nut 1  
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