Manual gearbox - primary, idler and 1st motion shaft drive gears

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Primary (Output), Idler and 1st Motion Shaft Drive (Input) Gears
Several different combinations of primary gear and bushes were used on the earliest Mini power units built between 1959 and 1963, following the abject 
failure of the first, the so-called 'D.U.' bush and oil seal design (which allowed engine oil seepage onto the clutch all too frequently).  As an interim measure, 
a revised oil-fed bush system was fitted - in most cases when the car came in for the inevitable clutch replacement - and after a couple of false starts the 
'Deva' dry-lubricated bush became the standard fitment.  Each system necessitated a different engine crankshaft and flywheel, as well as the primary 
gear and bushes.  Extra care must be taken to select matching components for these early designs.   
         
From 1963 onwards, crankshaft, flywheel, primary gear and bush combinations settled down into two designs, depending on the crankshaft tail dimensions: 
one combination for 848, 998 and 1098 engines and the other for 1071, 1275 and 970 engines.  This continued right the way through to 1979 when 'A Plus' 
gears were introduced, which saw production out through to 2000.        
         
Primary gears are supplied with their bushes fitted, as ready-to-use assemblies.  However, if you intend to fit replacement bushes in a primary gear, the 
bushes must be machined after fitment to ensure alignment with each other.     
         
By contrast, the idler and 1st motion shaft drive gears saw far fewer changes, being limited to 3 synchro gearbox (1959-68), pre-A Plus 4 synchro gearbox
(1968-79) and A Plus (1979 on).  Of these, pre-A Plus 4 synchro gears may be used on 3 synchro gearboxes if certain other components are fitted at the
same time.  However, pre-A Plus and A Plus gears cannot be mixed and matched together.    
         
Bearings (and their retaining circlips) for the idler and drive gears may be found in the 'Flywheel Housing and Clutch Cover' and 'Manual Gearbox - External' 
sections of this catalogue.  Primary, idler and drive gears for automatic Minis may be found in the 'Automatic Transmission - Torque Converter and Housing' 
section.        
         
Primary Gears      
1959-62, Oil-fed Bush Type 848 Engines    
Ill. No. Part No. Description Qty. Rqd. Remarks
1 22A79 PRIMARY GEAR ASS'Y, with bushes, 24 teeth 1  
2 22A81 BUSH, primary gear, front 1  
3 22A82 BUSH, primary gear, rear 1  
         
1961-62, Oil-fed Bush Type 997 Engines    
Ill. No. Part No. Description Qty. Rqd. Remarks
4 12A380 PRIMARY GEAR ASS'Y, with bushes, 24 teeth 1  
5 12A386 BUSH, primary gear, front 1  
6 12A385 BUSH, primary gear, rear 1  
         
1962-63, Deva Bush Type 848 Engines With 1 3/8" dia. Flywheel Machining    
Ill. No. Part No. Description Qty. Rqd. Remarks
7 22A520 PRIMARY GEAR ASS'Y, with bushes, 24 teeth 1  
8 22A447 BUSH, primary gear, front 1  
9 22A448 BUSH, primary gear, rear 1  
         
1962-63, Deva Bush Type 997 Engines With 1 3/8" dia. Flywheel Machining    
Ill. No. Part No. Description Qty. Rqd. Remarks
10 22G106 PRIMARY GEAR ASS'Y, with bushes, 24 teeth 1  
11 22G108 BUSH, primary gear, front 1  
12 22G109 BUSH, primary gear, rear 1  
         
1963, Deva Bush Type 997 and 998 Engines With 1 1/2" dia. Flywheel Machining  
Ill. No. Part No. Description Qty. Rqd. Remarks
13 22A551 PRIMARY GEAR ASS'Y, with bushes, 24 teeth 1  
14 22A553 BUSH, primary gear, front 1  
15 22G109 BUSH, primary gear, rear 1  
         
1963-92, Deva Bush Type 848,  998 and 1098 Engines With 1 1/2" dia. Flywheel Machining  
Ill. No. Part No. Description Qty. Rqd. Remarks
16 22A1493 PRIMARY GEAR ASS'Y, with bushes, 24 teeth 1 1963-79.
  DAM8888 PRIMARY GEAR ASS'Y, with bushes, 29 teeth 1 1979-92; A Plus.
17 DAM2821 DUST SHIELD 1 1979-92; A Plus.
18 DAM8887 BUSH, primary gear, front 1  
19 22G109 BUSH, primary gear, rear 1  
         
1963 On, Deva Bush Type 1071, 1275 and 970 Engines With 1 1/2" dia. Flywheel Machining  
Ill. No. Part No. Description Qty. Rqd. Remarks
20 22G1053 PRIMARY GEAR ASS'Y, with bushes, 24 teeth 1 1963-79.
  DAM8890 PRIMARY GEAR ASS'Y, with bushes, 29 teeth 1 1979 on; A Plus.  Not France, 1990-96.
  DAM9373 PRIMARY GEAR ASS'Y, with bushes, 30 teeth 1 A Plus.  France, 1990-96.
21 DAM2821 DUST SHIELD 1 1979 on; A Plus.   
22 DAM8889 BUSH, primary gear, front 1  
23 22G109 BUSH, primary gear, rear 1  
         
Primary Gear Front Thrust Washers    
848, 997, 998 and 1098 Engines, Except 848 Engines 1962-63    
Ill. No. Part No. Description Qty. Rqd. Remarks
24 22A321 WASHER, thrust, primary gear, front 1 0.110-0.112" (2.79-2.84mm).
  22A322 WASHER, thrust, primary gear, front 1 0.112-0.114" (2.84-2.89mm).
  22A323 WASHER, thrust, primary gear, front 1 0.114-0.116" (2.89-2.94mm).
  22A324 WASHER, thrust, primary gear, front 1 0.116-0.118" (2.94-2.99mm).
  22A450 WASHER, thrust, primary gear, front 1 0.118-0.120" (2.99-3.04mm).
         
848 Engines 1962-63      
Ill. No. Part No. Description Qty. Rqd. Remarks
25 22A295 WASHER, thrust, primary gear, front 1 0.123-0.125" (3.12-3.17mm).
  22A83 WASHER, thrust, primary gear, front 1 0.125-0.127" (3.17-3.22mm).
  22A238 WASHER, thrust, primary gear, front 1 0.127-0.129" (3.22-3.28mm).
  22A239 WASHER, thrust, primary gear, front 1 0.129-0.131" (3.28-3.32mm).
         
1071, 1275 and 970 Engines    
Ill. No. Part No. Description Qty. Rqd. Remarks
26 DAM6490 WASHER, thrust, primary gear, front 1 0.112-0.114" (2.84-2.89mm).
  DAM6486 WASHER, thrust, primary gear, front 1 0.114-0.116" (2.89-2.94mm).
  DAM6487 WASHER, thrust, primary gear, front 1 0.116-0.118" (2.94-2.99mm).
  DAM6488 WASHER, thrust, primary gear, front 1 0.118-0.120" (2.99-3.04mm).
  DAM6489 WASHER, thrust, primary gear, front 1 0.120-0.122" (3.04-3.09mm).
         
Primary Gear Rear Thrust Washers    
1959-62, Oil-fed Bush Type 848 Engines    
Ill. No. Part No. Description Qty. Rqd. Remarks
27 2A3597 WASHER, thrust, primary gear, rear 1  
         
1961-62, Oil-fed Bush Type 997 Engines    
Ill. No. Part No. Description Qty. Rqd. Remarks
28 12A382 WASHER, thrust, primary gear, rear 1  
29 12A383 RING, backing 1  
         
1962-63, Deva Bush 848 Engines With 1 3/8" dia. Flywheel Machining.  
Ill. No. Part No. Description Qty. Rqd. Remarks
30 2A3597 WASHER, thrust, primary gear, rear 1  
31 22A449 RING, backing 1  
         
1962 On, Deva Bush 970, 997, 998, 1098, 1070 and 1275 Engines With 1 3/8" or 1 1/2" dia. Flywheel Machining
1963 On, Deva Bush 848 Engines With 1 1/2" dia. Flywheel Machining    
Ill. No. Part No. Description Qty. Rqd. Remarks
32 22A319 WASHER, thrust, primary gear, rear 1  
33 88G549 RING, backing 1  
         
Idler Gears      
Ill. No. Part No. Description Qty. Rqd. Remarks
34 22A304 IDLER GEAR, 31 teeth, 3/4" shaft dia. 1 1959-68; 3 synchro.
  22G943 IDLER GEAR, 31 teeth, 3/4" shaft dia. 1 1968-79; 4 synchro.
  TUB101310 IDLER GEAR, 37 teeth, 7/8" shaft dia. 1 1979 on; 4 synchro, A Plus.
The 3 synchro 22A304 idler gear may be replaced by the equivalent gear from the 4 synchro gearbox, 22G943, so long as the original circlip retaining the idler gear bearing in the gearbox case is replaced with a 22G1141 circlip.
         
Ill. No. Part No. Description Qty. Rqd. Remarks
35 22A1545 WASHER, thrust, 0.130-0.131" (3.30-3.32mm) 2 1959-79; 3 synchro and 4 synchro.
  22A1546 WASHER, thrust, 0.132-0.133" (3.35-3.37mm) 2 1959-79; 3 synchro and 4 synchro.
  22A1547 WASHER, thrust, 0.134-0.135" (3.40-3.42mm) 2 1959-79; 3 synchro and 4 synchro.
  22A1548 WASHER, thrust, 0.136-0.137" (3.45-3.47mm) 2 1959-79; 3 synchro and 4 synchro.
  22A1549 WASHER, thrust, 0.138-0.139" (3.50-3.53mm) 2 1959-79; 3 synchro and 4 synchro.
  DAM5914 WASHER, thrust, 0.130-0.131" (3.30-3.32mm) 2 1979 on; 4 synchro, A Plus.
  DAM4822 WASHER, thrust, 0.132-0.133" (3.35-3.37mm) 2 1979 on; 4 synchro, A Plus.
  DAM4823 WASHER, thrust, 0.134-0.135" (3.40-3.42mm) 2 1979 on; 4 synchro, A Plus.
  DAM4824 WASHER, thrust, 0.136-0.137" (3.45-3.47mm) 2 1979 on; 4 synchro, A Plus.
  DAM4825 WASHER, thrust, 0.138-0.139" (3.50-3.53mm) 2 1979 on; 4 synchro, A Plus.
         
1st Motion Shaft Drive Gears    
Ill. No. Part No. Description Qty. Rqd. Remarks
36 2A3545 DRIVE GEAR, 1st motion shaft, 24 teeth 1 1959-68; 3 synchro.
  22G849 DRIVE GEAR, 1st motion shaft, 24 teeth 1 1968-79; 4 synchro.
  DAM2925 DRIVE GEAR, 1st motion shaft, 29 teeth 1 1979 on; A Plus.  Not 1275 (France), 1990-96.
  DAM6337 DRIVE GEAR, 1st motion shaft, 28 teeth 1 A Plus.  1275 (France), 1990-96.  
The 3 synchro 2A3548 drive gear may be replaced by the 22G849 gear from the 4 synchro gearbox, so long as distance piece C-STR239 is also used.
         
Ill. No. Part No. Description Qty. Rqd. Remarks
37 2A3548 NUT, drive gear to 1st motion shaft 1  
38 DAM4000 LOCK TAB 1  
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