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MG Midget and Sprite Technical - fitting 3rd gear

I’m slowly working my way through a gearbox rebuild but am now stuck getting the retaining collar back on third gear.

How on earth do you push in the plunger, hold it in and then push the collar into place? I’ve tried using a very small screwdriver but there just isn’t enough clearance. Starting to think that I may need to make some kind of tool with a 90 degree bend in it.

Cheers

Rob
Rob Storer

It's a long time since I've done one, but I seem to remember a small screwdriver was the tool for the job!
Dave O'Neill 2

tiny probes (like dental picks), and three hands can possibly do it, but the real el-magic-o tool is a scrap one of those rings with the edges of those slots filed down into ramps. You use that scrap one to get the spring and plunger into position, and then you slide the original ring over to replace it. It makes a heck of an annoyingly difficult job into a 5 second breeze.

The trick is to find someone with a scrap ring that you can do that to.

Anyone got a scrap gearbox who can share?

When I did it I was at a gearbox rebuilding class at University Motors, in Ada, Michigan, so I won't be much help to you beyond providing the idea...

Norm Kerr
Norm Kerr

Thanks for the suggestions I think I will look at fabricating a suitable implement. Glad I’ve moved on from the days when you had to have it all back together for work Monday morning.
Rob Storer

Here is a link to a post I wrote that may help. It's on replacing second gear that has the @#$% opposing plungers. I have not replaced 3rd, but it looks similar.

They problem with getting anything in there is the synchro cone pretty much blocks where you really need to push.

Good luck!

http://www.mgexperience.net/phorum/read.php?3,1382912
CJCharvet

Rob

I use a crude but simple and effective tool: A thin nail (1.5" x 1/16" diameter panel pin, end squared off) held in locking pliers. I have a pin punch I could use, but this arrangement has proved easier to hold while keeping pressure on the plunger.

The nail being reasonably high tensile wont bend. It will depress the plunger OK and is thin enough to allow the lock washer to get on far enough to engage the plunger, then you can withdraw the nail and slide the lock washer the rest of the way.

Here my memory fails me a bit ... I know the Mini gearbox, which is basically similar, has a small angled relief groove on the back of the lock washer which makes more room for the nail and so the job much easier, can't remember if the midget version of the gbox has. If not I suggest you add one!

Lini the groove up with the plunger, then the whole lot takes 10 seconds. Unlike the second gear double plunger!
Paul Walbran

I used a TIG welding material rod, flattened to a sort of scoop and a bend in it so it would curve between the ring and hub
Alex G Matla

Paul,

I managed the second gear double plunger using a method similar to CJCharvet and thought if I can do that the rest will be easy! You’re right about the grouve but the angle is still wrong to get the ring far enough down due to the height of the syncro cone.

The message I’m getting is that it’s all about the tool you use, when I’m in the right frame of mind I have another go.

Thanks to all of you for your replies
Rob Storer

This thread was discussed between 19/07/2010 and 21/07/2010

MG Midget and Sprite Technical index

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