Series 3 109 Six Pot Rebuild Thread

[Wagon Loon]

Well I hope your cognitive skills are working well lol.
That's a lot of work you've done, and I've no doubt inches of grime removed too.
Many of the gears looking good from what can be seen, good luck finding Any replacement pairs needed. The quality Italian bearing sets and seals are very reasonably priced I thought, but gears can be rather expensive.
I hope you can find all your parts and that it all goes back together well.

 

[LincolnSteve]

I find that many bits of gearbox, loose on the bench just terrifying!

 

[BikerB]

Well, another project that is now generally back together which had even more parts was this-

It currently looks like this

Actually its a bit further forward than that pic but essentially all the mechanical bits are back together.
I have a Cyclemaster in bits along with a Matchless G11 I bought in boxes underneath the stripped shell of an MG Midget in the workshop so "kit builidng" is just my thing, a Landrover gearbox, assuming I have identify the suffix of some of the internal parts, is pretty tame

 

[BikerB]

Well, winch fitted today, short a couple of bolts for the recovery loops but I'll get them ordered.

Towbar was fitted a while ago, galved and painted and the reinforcing bar remade and galved, I have one of those brackets to fit the electrics into the output hole so need to finish that. The actual towball mount was toast so will buy a new one of them near the end of the build.

rear axle fitted, clearances checked and a new rear cover fitted, still need to do the pinion seal but I left that until the wheels are on so I can get the necessary oomph applied and can lock the wheels.

Still plodding along with other small parts, this is the rebushed and refurbished handbrake linkage.

Next is the brake backplates and stub axles so I can get the brakes finished and get it back on its wheels. I need to start thinking about paint soon so I ca fix things like the rad panel and paint them to fit.

 

[BikerB]

Spent a week or two learning about LT76 gearboxes to source the bits needed, have most of them here and the rest on their way so can start putting in back together again shortly. You can ask me just about anything about LT76 suffixes now while I remember but in about a months time I will have forgotten!
I decided to build 3/4 as Suffix D and leave the rest as Suffix B, ebven get get 95% of the bits including the gears very cheap and genuine.
Since the front and rear of the mainshaft are separate and different and I have a suffix D layshaft I could see any reason why I couldn't "mix and match" so to speak so I am going to. Needed to replace the 3/4 synchro anyway. Hopefully this will help with the usual 3rd popping out on overrun, or at least go some way to help it.
I'll put some pics up when I start reassembly as I go along soon.

 

[BikerB]

Gearbox started to go back together tonight, although speed will depend on how quick the outstanding parts arrive, not quick with the current local postal strike I think.
Got the main and layshaft bearings in tonight so the cases are ready for the shafts once built, Found my reverse had a chip in one tooth though, buggeration! I have checked it but underneath a bit of dirt I found one single tooth had a corner chipped out of it, other wise it looks like new, I hadn't ordered one so although they are cheap there is going to be a further delay as it isn't in any of the parcels on their way

It certainly helps have a good press

That's them ready, now can get a few bits painted awaiting the rest of the parts, and reverse gear!

 

[BikerB]

Got most of the bits here now for the main box, just sourcing a 1/2 synchro and a 2nd gear and thats the last of them. every seal, gear and bearing brand new genuine LR parts sourced from many places. I haven't found these last two parts yet but still hopeful, if not I know where I can get Italian ones which are supposed to be the next best thing.
Once I have them I can finish the gearbox then move onto the Transfer box and OD but my initial inspection looks like they will juct get seals and bearings after a good clean. The gearbox only ended up needing so many bots because I wanted to build it to suffix D, I have most of a suffix B box now as spares that are just to good to bin.

 

[BikerB]

Had a look now I am back from being away tonight and managed to find a genuine NOS 2nd gear which is now on its way, just the 1/2 synchro unit to find now.......

 

[BikerB]

Had to give up and get a 1/2 in out unit as an OEM Italian one as I can't find an original NOS one. Still every bit in the main gearbox is genuine NOS apart from that and the eytie ones are supposed to be very good.
Should be able to start assembling by next week and get the main box together.
I could have used most of the original bits but ended up simply replacing everything in the main box as I kept thinking "I have replaced that so may as well replace that as well" At least it will be fully upgraded to Suffix D rather than the original Suffix B spec.

 

[BikerB]

I got a NOS 571218 LR 2/3 gear bronze bush today as I found that Rover P4's used them under a different part number so I didn't have to use one of the pattern ones after all.
The original parts are still out there if you look hard enough but are getting harder to find.............

 

[BikerB]

So all the gears now available, just awaiting a genuine NOS bush to turn up. All genuine original parts apart from the 1/2nd gear synchro which is italian, I couldn't find a genuine one except at completely bonkers prices.

The genuine reverse gear and bearing is already in the main case, along with the input shaft, the internal shafts are here awaiting final assembly.

slowly cleaning and painting all the other little bits ready to go as well

As soon as the bush turns up I can reassemble the main gearbox, then move onto the transfer box which I have been gathering parts for, then the Overdrive. This box will be pretty much the nearest I can reasonably get to a genuine brand new box using genuine parts, upgraded from the original Suffix B to Suffix D internally,

 

[BikerB]

Finally got the NOS bush today and started assembling the mainshaft, or so I thought as the bush is too short and I have my doubts about it being genuine
So sending it back and I still need a bush which seem to be in short supply.
Put a few bits of the transfer box together since I was in the workshop but a bit stumped about the bush on the main box. Reluctant to use the two piece (pre broken) bushes as I can't figure out what stops half of it twirling around the mainshaft in use, or am I missing something?

 

[BikerB]

Still plodding along, what with delays to get parts and the odd cock-up.
Gearbox coming together although I had one error when putting it together that cost me, even then my box should be as close to a new one as possible and still a lot cheaper than a recon one, even though the mistake cost me about £150 in replacing the replacement parts!
Unfortunately the mainshaft components dropped slightly out of alignment when in the press and the press kept pressing, it didn't feel right so I pulled it back out and discovered one damaged syncro ring and one damaged 1/2 synchro unit. You live and learn
Anyway The transfer box is ready for bolting on and as soon as the 1/2nd unit turns up, hopefully tomorrow, the main gearbox just needs assembling.and bolted to the transfer box and its all over bar the shouting, and there has been plenty of that.
Need to start the overdrive next, althougth I have been struggling with some of the parts needed, anybody know someone who has a clutch RTC7170 actually in stock?
Anyway, getting there but can't upload pics?

 

[LincolnSteve]

Sorry to hear about the problems. There must be easier hobbies mustn't there? Knitting anyone?

 

[BikerB]

Its not a problem, sometimes things go wrong or not completely happy with fits. Thie only good thing is that even with mistakes and breaking the odd bit at least when it is done you have two bits of satisfaction.
It is a lot cheaper than paying someone to do it
You end up knowing every nut and bolt and know that it is done right.
I know how to avoid making the mistake again so something new learned each time
I am just awaiting the new 1/2 unit to turn up, frustratingly I got a new EAC one for £50 less than I paid for the original identical one from a different supplier
Its only my second gearbox and I suppose in some ways because of the OD and transfer box you could actually call it my 2nd, 3rd and 4th boxes!

 

[BikerB]

Its all back together again, just need to make a couple of gaskets to put on a couple of covers and fit the transmission handbrake parts which are all rebuilt and painted ready to go.
I only made two mistakes, pressing in the mainshaft to the case it moved and the press knackered the in/out mech and one synchro ring (about £150 of parts needing replaced, again) and I thought I was being smart and fitted the transfer case to the main gearbox first, thinking it would be easier to hump the parts around on the bench. Oops, you can't fit the front output casing on afterwards, it fits behind the main gearcase. Still that was only a couple of quid for a new gasket!
I reckon it probably cost me about a grand all in which is about 2/3rds of the cheapest decent recon I could find, plus mine has no britpart parts or cheap bearings in it and about £170 of that was the roamerdrive upgrades.
Its al done now and is fully updated to Suffix D, almost all new NOS parts, has the roamerdrive transfer case plate fitted and this week the roamerdrive transfer case dipstick mod. Just need to do the overdrive and bolt it on and the whole thing can get dropped on the chassis ready for the props.
I'll try and get pics this week if the pic thingy is working again.

 

[BikerB]

Just starting on the Overdrive now, cleaned it off and starting to take apart for inspection. Bit worried that there was no oil in it

I ended up making the extension cover on the front output casing out of 2mm plate and tube rather than buy a new one, the old one was like swiss cheese but at least now it will take a while for the new one to rust through

 

[LincolnSteve]

Save pictures somewhere else then copy and paste straight in. Seems to be the best way at the moment.

 

[BikerB]

Finally got all the bits ordered to do the OD, new mainshaft arrived and the new clutch sleeve and all the bearings and seals on their way. Hopefully get the OD built and bolted to the back and thats the gearbox fully finished ready to drop into the chassis, right down to the clutch release bearing and ancilliaries.
When I stripped it down I found the usual mainshaft spline/clutch sleeve wear so had to replace both, however the rest looks good and it seem to be just a case of new seals and bearings and reassemble.
So it looks like I should end up with a more or less perfect OD for about £650 including buying it in the first place, which makes most of the ebay prices look a tad expensive for unknown condition units.
I'll put up pics as i rebuild once the last bits arrive.
I am also starting to sort out getting the chassis into the workshop to speed up work, for six months its too cold, dark and damp to do much out in the garage tent and I want to speed up the build, now if I can figure out where to put everything else it will be golden!

 

[GSF 109]

Great build there. Looking forward to seeing the rolling chassis again with a gearbox in it.