Gearbox 1.

Although we did not have the correct original gearbox in the car, luckily we had an Innocenty Cooper Export unit, which is identical internaly as the original, just in a rod change housing. This gave most of the hard-to-find parts for an original setup. We also needed a remote change 4 syncro gearbox case, and some internals. Luckily I had one in my shed, collecting dust a few years now. This is 90%. The rest 10% was a bit of a problem. The Inno had the late pot type inner driveshaft joint, the 4 syncro came from a plain 1000ccm modell, thus had the rubber cross type, unlike the Cooper S, which had the hardy spicer joint. The parts that are available new, we bought, but still there are 3 parts that are not available of the shelf. Theese we got from a mini racer, whom we are very gratefull for this, and as soon as possible we will give them back :-).

Rebuilding the gearbox on a mini is not a one afternoon job, and although it might look easy, need a bit of attention at some points. Especialy if You would like to do it only once.

First I cleaned everithing. This time I took a chance with the dishwasher. Although it was technicaly a success, I am not sure how many times the Wife will forgive it to me.

I have a couple of dismantled gearboxes, I wanted to pick the best parts with as few wear as possible. Take care: 3 syncro and 4 syncro box parts might look similar, but they are not always interchangeable (dont ask me how I learned this).

Nice clean case just out of the paint cabinet. Case inspected for damage on the sealing surfaces, at the bearings and at some places for cracks. 

With some parts the condition is obvios, but some parts need to be investigated quite close.

All the gears inspected outside...

...and inside for wear.

Old sycro rings were definitely worrn. Look at the gap between the ring and the gear here...

...and here with the new item.

As a final point the gearbox mainshaft was checked for straightness.