About Morris Mini Magic Wand Gear Overhaul

[jaden]

hello.
Please understand that I am posting through a translator.
I am currently operating the Morris Mini Traveler Woody.
I recently overhauled the engine and mission, but when I assembled the engine, first gear won't engage.

It has a magic wand gear method.
I want to purchase all the parts that can be overhauled, but it is difficult in Korea (South Korea).

Please tell me all the part numbers that can restore the magic wand gearbox.
Out of 1,2,3,4 gears, 1 gear is not working.

I also bought a clutch this time and it is very difficult to get a Mini in Korea...

Please help me...

[MagicWandWoody]

I'm far from expert but...

I think that gearbox (casing number 22G68) has synchro only on gears 2nd, 3rd, 4th, but not on 1st. So perhaps, if you have another minor fault (e.g. a dragging clutch) this may be why you are finding it more difficult to engage 1st than the other gears?

There are also two different gearbox types with the same casing number ("type A" and "type B"). Many of their internals are not compatible, so that will make it even more difficult for you to find the correct parts, if you need them.

The parts picture that you've attached appears to be for a different (4-sychro) gearbox?

[gs.davies]

Can you be more specific with the fault?

Under what conditions will it not engage first? With the engine running? With the engine stopped? Will it engage other gears?

What’s the state of play with the clutch? Is that correctly adjusted? Is the clutch plate disengaging when the pedal is pressed?

[jaden]

I'm far from expert but...

I think that gearbox (casing number 22G68) has synchro only on gears 2nd, 3rd, 4th, but not on 1st. So perhaps, if you have another minor fault (e.g. a dragging clutch) this may be why you are finding it more difficult to engage 1st than the other gears?

There are also two different gearbox types with the same casing number ("type A" and "type B"). Many of their internals are not compatible, so that will make it even more difficult for you to find the correct parts, if you need them.

The parts picture that you've attached appears to be for a different (4-sychro) gearbox?

Thanks for your reply.
My gearbox is 22G68.
Can you tell me the parts that can be used to overhaul my gearbox?
I don't know if it is type A or type B.

[jaden]

Can you be more specific with the fault?

Under what conditions will it not engage first? With the engine running? With the engine stopped? Will it engage other gears?

What’s the state of play with the clutch? Is that correctly adjusted? Is the clutch plate disengaging when the pedal is pressed?

Thank you very much for your reply.
There is no problem with starting the engine.
After the engine starts, when I press the clutch pedal, the first gear does not go in.
It makes noise and the first gear is not entered.

The stamp on the gearbox is 22G68.
The synchro gear is worn. Can you help me find the part to replace it?

Please.

[Spider]

Unfortunately, there was lots of changes in production over a short period of time.

As a result, there were 2 main types of gear trains used in these gearboxes and even within them, several modifications in each series.

Many parts for these are hard to come by and you won't know exactly what you need until you strip the gearbox.

Given where you are and the overall circumstances, you'd be best off buying a complete overhauled gearbox and importing it to Korea.

I'd suggest reaching out to Jason on the forum.

[MagicWandWoody]

After the engine starts, when I press the clutch pedal, the first gear does not go in.
It makes noise and the first gear is not entered.

The stamp on the gearbox is 22G68.
The [1st gear] synchro gear is worn. Can you help me find the part to replace it?

Please.

On that gearbox I don't think there is a synchro on 1st gear, so it cannot be worn. So it is a bit too soon to start taking the gearbox apart, yet. With those symptoms, I would first try adjusting the clutch to get more throw in case it is dragging. If that does not help I would check to see if the [new?] clutch is correctly assembled with the correct parts and whether it might have heavy oil contamination from a leak. I'd also want to be sure that the oil is the correct type and amount.

[jaden]

Unfortunately, there was lots of changes in production over a short period of time.

As a result, there were 2 main types of gear trains used in these gearboxes and even within them, several modifications in each series.

Many parts for these are hard to come by and you won't know exactly what you need until you strip the gearbox.

Given where you are and the overall circumstances, you'd be best off buying a complete overhauled gearbox and importing it to Korea.

I'd suggest reaching out to Jason on the forum.

Thanks for your reply.
I am looking for a fully functioning gearbox.
How can I contact Jason?
I am still having trouble with the website.
Can you ship to South Korea?
I need a gearbox that fits my engine right now.

Please help me contact Jason.
Paypal, eBay, various terms are available.

[jaden]

After the engine starts, when I press the clutch pedal, the first gear does not go in.
It makes noise and the first gear is not entered.

The stamp on the gearbox is 22G68.
The [1st gear] synchro gear is worn. Can you help me find the part to replace it?

Please.

On that gearbox I don't think there is a synchro on 1st gear, so it cannot be worn. So it is a bit too soon to start taking the gearbox apart, yet. With those symptoms, I would first try adjusting the clutch to get more throw in case it is dragging. If that does not help I would check to see if the [new?] clutch is correctly assembled with the correct parts and whether it might have heavy oil contamination from a leak. I'd also want to be sure that the oil is the correct type and amount.

Thanks for your reply.

I bought a clutch set from Mini Spare.
After completing the engine assembly and starting it, there was a noise.
After looking at it again, I found that the shape of the clutch plate was a bit off from the original.

I ordered a new clutch separately from Mini Spare.

[Spider]

Thanks for your reply.
I am looking for a fully functioning gearbox.
How can I contact Jason?
I am still having trouble with the website.
Can you ship to South Korea?
I need a gearbox that fits my engine right now.

Please help me contact Jason.
Paypal, eBay, various terms are available.

You can contact Jason here;-

memberlist.php?mode=viewprofile&u=11406

Just to check with you here, as others have mentioned, you do realise that 1st gear is not synchromesh ? This means you need to come to a dead stop to engage 1st gear.

Also a qurk with these gearboxes is when at a stop, you can engage 1st, however they usually go in easier, if you select 2nd, then 1st gear.

[roger mcnab]

hi when i was in the nsw fire brigade we had dennis jag appliancesq with 5 speed gear boxes if you started in first gear you had to stop completely to get 2nd so we always started in 2nd which did not worry the performance at all great appliance with hopeless brakes
cheers roger

[Jason]

After messages about the gearbox, I have told Jaden to put the issues here that he is having with the clutch after replacing various parts so that we can try to help out.
Difficulty in engaging first gear when stationary, I think is due to the clutch not fully dis engaging and sending some load through the drop gears - then the laygear is rotating while trying for first. First gear can be achieved, but grabs as it goes in.Reverse gear also has the same symptom.
Engine off and first gear and reverse goes in no problem, so not a selector issue.
Engine running, 2nd, 3rd and 4th gear selection is no issue. I have seen pictures of first gear outer track and laygear and although there is a small amount of wear, the drive teeth are in good condition.

[jaden]

After messages about the gearbox, I have told Jaden to put the issues here that he is having with the clutch after replacing various parts so that we can try to help out.
Difficulty in engaging first gear when stationary, I think is due to the clutch not fully dis engaging and sending some load through the drop gears - then the laygear is rotating while trying for first. First gear can be achieved, but grabs as it goes in.Reverse gear also has the same symptom.
Engine off and first gear and reverse goes in no problem, so not a selector issue.
Engine running, 2nd, 3rd and 4th gear selection is no issue. I have seen pictures of first gear outer track and laygear and although there is a small amount of wear, the drive teeth are in good condition.

Hello, I have been having trouble solving the problem for several days.
The current problem is that the clutch pedal does not cut off power.
Even if I make a pin like the picture, the problem was not solved.
Why does the clutch pedal not cut off power?
If I force the 1st gear to engage, it grinds, but it can be engaged.

[MagicWandWoody]

Could we see pictures of all the parts, please? Including the cover-plate, with the clutch release lever, and the slave cylinder?

[jaden]

Could we see pictures of all the parts, please? Including the cover-plate, with the clutch release lever, and the slave cylinder?

I'm planning to take the engine down again on the 12th. I'll attach some pictures then.

[MagicWandWoody]

Could we see pictures of all the parts, please? Including the cover-plate, with the clutch release lever, and the slave cylinder?

I'm planning to take the engine down again on the 12th. I'll attach some pictures then.

Pictures with the engine fitted in the car can still be of help. Others (much more experienced than me) here may spot something useful. The more pictures the better.

At the moment, my wild ideas are:
- A mixture of Verto and non-Verto components.
- A faulty clutch master cylinder. Or a 0.7" brake master wrongly fitted instead of a 0.75" clutch master. (Is that mistake physically do-able or are the bolt patterns different?)
- A faulty slave cylinder.
- A faulty flexi hose.
- Poor bleeding.
- Throw-limiting nut adjusted too tight - the 1/4" specification is only a rough guide, once the lever gets worn. Mine, for example, is set at 7.5mm.

These things can be checked without removing the engine from the car and, you never know, you might be lucky and find the fault without having to take the engine out again.

[Spider]

Sounds like the Primary Gear is binding on the Crank.

Has it had the Primary Gear Bushes replaced or a new one fitted ?

[hugbilly]

Have to say that on my 3 synchro '61 I always had to engage second briefly before putting the car into first gear when stationary otherwise there would be a graunch.

Going from second to first when underway of course required a proper double declutch . . .

[MagicWandWoody]

Did this get solved? Is there now a Mini on the road in Korea?