Thread: Series gearbox assessment

I’d personally dump the oil and inspect at the very least. You can check wear and tear and endfloat at this point. They’re out of the car which makes it so much easier.
I’m pretty sure you can buy gasket kits for them easily and bought too. At worst you could make one out of a cardboard box if you didn’t want/need the whole set.

Gasket set is available that covers gearbox & transfer box.
Series III box has synchro on 1st & 2nd, Series II didn’t unless very, very late.

You’ll be able to pick up some issues on the bench but some may only show up under load.
Synchro springs are a regular item that fails.
Check all bearings for noise.
Check for chipped gear teeth.
Check for wear on the synchro teeth & synchro rings.
Replace seals.

If it’s possible to fit it to a vehicle this would confirm it’s OK without stripping down.

Colin

As Chops says - first drain the oil and have a look at what comes out with it.

I would also remove cover plates (main gearbox top and bottom plate of T/C and have a good look. Look for abnormal wear on any of the gears. On the S3 box look for missing spring clips on the synchro, and for both try and assess wear on the synchro (not easy unless you are familiar with it).

Check also for sideways movement on either output shaft, and also the input shaft (there will be some on the input shaft, should be none on the others). While you are at it, probably a good idea to replace both output shaft seals and the condition of the sealing surface on the output flanges. And also check the handbrake condition.

Thanks gents, you’re both evergreen stalwarts for those bold enough to step into the unknown.
I’ve taken off the t/c cover plate and so far so good. The gaskets are newish and show blue gasket, and I vaguely recall the previous owner mentioning some work had been done?!?!?
How much play is acceptable between the low gear wheel and the output to rear axel shaft? The teeth all look good and I guess there must be a bit of tolerance to allow the gear to slide along the shaft???
I will open the gearbox tomorrow and take a gander at the gears.