Manual gearbox - 4 synchromesh internal components

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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Manual gearbox - 4 synchromesh internal components

NUT- DIFF PINION TO MAINSHAFT. PRE A+

BUSH-REVERSE IDLER-A+

REVERSE IDLER-ROD CHANGE-A+

PINION-FINAL DRIVE-21 TEETH-A+

SHAFT-REVERSE IDLER-ALL GEARBOXES

NUT-DIFF PINION TO MAINSHAFT-A+

MAINSHAFT-(3rd MOTION)-4 SYNCHRO A+

SYNCHRONISER-3rd & 4th GEAR- 4 SYNCHRO GEARBOX

SYNCHRONISER-1st & 2nd GEAR-4 SYNCHRO GEARBOXES

SHAFT-1st MOTION-16 TEETH-A+ '90-'96 1275cc FRANCE

GEAR-3rd SPEED-20 TEETH-1275 A+ '90-'96- FRANCE

GEAR-2nd SPEED-25 TEETH-A+ '90-'96 1275 FRANCE

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