Dom's 109" (re)build

samc88 · May 9, 2015

Bearmachs pretty good. Ive got a bearmach 3rd/ 4th synchro on mine when I rebuilt that last year. Only genuine bits on my gearbox are the layshaft, mainshaft, timken bearings, Corteco seals. 1st/ 2nd synchro can be rebuilt with new synchro springs and things.

Cost me £300 in total

My thread on it here http://ollr.createaforum.com/technical-tips-questions/sam's-gearbox-overhaul/

dominicbeesley · May 10, 2015

Thanks Sam, good thread there I'll be referring to it in the near future no doubt. The most expensive part that I need is the 1st/2nd synchro main part RTC2685 which is destroyed on mine. LRDirect have Britpart and Bearmach coming out at ~£70 and genuine at £134 (although the description for the genuine says its a spare wheel bracket!)

I'll probably go for Bearmach then. Where did you get your bearings? I'd like to use decent timkens or similar. The input shaft bearing feels very loose and sounds gritty so that definitely needs doing which makes me suspect that all the others are duff.

D

samc88 · May 10, 2015

I got my bearings from a few different places, i think most were from craddocks but not sure.

honolulujoe · May 10, 2015

land Rover Series 3 88" 109" 4 cyl Gearbox Good used condition FreeUK shipping | eBay

good looking used one here £375 posted, was thinking about it but I bought that toro overdrive instead

onecelledcreature · May 10, 2015

honolulujoe said:
land Rover Series 3 88" 109" 4 cyl Gearbox Good used condition FreeUK shipping | eBay

good looking used one here £375 posted, was thinking about it but I bought that toro overdrive instead

"Nice quiet unit
Comes complete as shown"
they're being careful not to show the missing backplate, and no mention of the gearstick not being there either.

hope the buyer noticed that

honolulujoe · May 10, 2015

doh, it didn't even occur to me the stick wasn't there, must have had an od he robbed out, now you have said it I can see the back plate isn't there, that's a bit naughty "comes complete as shown" i would call that a deliberately misleading statement.

onecelledcreature · May 10, 2015

honolulujoe said:
doh, it didn't even occur to me the stick wasn't there, must have had an od he robbed out, now you have said it I can see the back plate isn't there, that's a bit naughty "comes complete as shown" i would call that a deliberately misleading statement.

hope you weren't the buyer then.

looking at their other items, just realised i bought one of their "rocket fuel" badges to replace the diesel fuel one a few years ago
the thing was a completely different size,

the seller refused to acknowledge any responsibility and fobbed me off.
maybe not to be completely trusted.

dominicbeesley · May 11, 2015

Thanks lads, just goes to show you'll not get what you want from ebay unless you're dead careful! I think I'm going to go for a rebuild, I might as well if dodgy ones are going to cost that much, plus delivery and fannying around. And £600 for a recon one is just too steep - I'm sure I can do a good job for less than that.

I've got two that need doing - the one in the daily driver is starting to jump out of gear and need a good long wait changing up from 2nd to 3rd.

I am tempted at the idea of getting one with an overdrive fitted though...

honolulujoe · May 11, 2015

luckily I didn't buy it

my gearboxes seem to be in good order - touch wood - I will get one of the 6 pot series 3 gearboxes if I see one when I have cash, apparently they bolt straight on to an s1 engine and full synchro would be nice

that chap has a nice looking od but I won't be buying anything from him now.

dominicbeesley · May 16, 2015

Well, I've started stripping down to see what I've got. This afternoon I got the transfer box off for a look and it doesn't look too bad except for maybe needing a new pair of thrust washers for the intermediate gear the bearings seem ok and the 4wd unit all looks good.

The thrust washers - do they have grooves cut in them or have they worn that way?

samc88 · May 16, 2015

Those thrust washers are well worn! Not sure on grooves, the spares downstairs have grooves but not to that extent

dominicbeesley · May 18, 2015

Thanks Sam,

I'm not sure if its been heavily used or there's just been bad oil in there - it looked like it had never been changed.

I'll try and remember a better camera next time and get some pictures of the gear and see what people think...they looked ok to me but I've not idea how worn is worn!

D

mrchurchill109 · May 18, 2015

Re: Thrust washers: Yup, worn out. if you see steel there's nothing left of the bearing surface.

As far as the gears, look for torn-up teeth (rough surfaces) or steps worn where the mating tooth rides. The standard of "wear" on something like this (as I was taught) is how much of the original tooth profile is gone to hell - if it's not stepped out or loking chewed up you can reuse it.

Rebuilding a gearbox and transfer is fun - it's precision work but reasonably straightforward. Do read the Green Bible and follow its tenets faithfully.

Alan

dominicbeesley · May 18, 2015

The green bible is always on hand and I do try to follow it.

The transfer box gears don't look bad and after a good clean up with parafin the intermediate shaft and gears looked pretty new. I can't feel any steps in the mating surfaces of the gears so I think the transfer box is good to bolt back up when I've finished cleaning it. The bearings feel ok and look ok too - not sure whether I should leave well enough alone there...

The gears in the main gearbox are a proper state.

mrchurchill109 · May 18, 2015

dominicbeesley said:
. The bearings feel ok and look ok too - not sure whether I should leave well enough alone there...

The gears in the main gearbox are a proper state.

Yep - not a huge surprise. Were it me I'd shoot them all just to have the satisfaction - but that is just me. I do have a press and all the splitters and such so for me it's not a trial - but if they feel good you can likely leave them in-situ in the transfer.

In the garabox though - the only goood used bearing is a discarded used bearing.

Alan

dominicbeesley · May 21, 2015

Cheers Alan,

I'm squarely in the leave well enough alone. They're Timken bearings that are fitted. I tapped out the bearings on the output shaft of the transfer box tonight and both races and rollers looked pristine so I put em back. I didn't take pictures of those.

I got a bit further, I stripped down the 4wd box and all seems well enough in there though the low gear selector fork does look a bit sorry I'm not sure its too bad, more that its a little corroded. I'm undecided whether that will be replaced. All the gears in the transfer box look and feel fine.

The thing that I've been wondering about tonight - is it possible to fit suffix-D gears and shafts to a suffix-B box or am I best leaving it as nature intended? any ideas?

D

Oldseadog · May 21, 2015

I'd be inclined to ask James Martin about compatibility, as he is the gearbox guru!

Are you up for a beer or two next Wednesday?

dominicbeesley · May 22, 2015

I may well be! I'll see if I can obtain clearance from control.

James certainly is the man - I've not seen him posting much on this bit lately. I'll try PM'ing him when I'm closer to the point of ordering stuff.

I got a bit further stripping down this afternoon - got the bell housing off and cleaned the transfer case. Hopefully I'll get a bit of time this weekend and will get everything laid out ready to decide what needs replacing...and remember to get batteries for the camera.

dominicbeesley · Jun 1, 2015

Well, I've had a bit of a few set-backs. The daily drive 88 failed it's MOT with a cracked chassis and so I've been busy trying fix that up. However progress of sorts was made this weekend when my mate spent a couple of hours chopping up the old chassis to make room. I'm not sure how small the pieces have to be but that will have to do for now as the plasma cutter tip has gone and I've lost the replacements...

nrgserv · Jun 1, 2015

wow, was the chassis so far gone

looked ok from the pics, but do know what ya mean when stuff's in the way.

Dom's 109" (re)build

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