worn reverse shaft, and gear with needle roller bearing

Some new bits have arrived - brass bushes, bearings, oil seals, first gear, layshaft, reverse idler shaft, springs, etc

first gear on the layshaft was badly pitted and worn (new on the left, old on right)

first gear from the mainshaft, the old one on the right shows some wear and the dog teeth were a bit worn

old bush on the top - new replacement underneath now comes in two halves because...

...the old one often snaps in half - you can just see the crack forming halfway down on this original one

Starting the re-assembly - first/second hub going back together with new springs (old ones bottom left)

went together far more easily than the Land Rover workshop manual made it sound...

using wet&dry paper on glass to grind down the end of a brass bush to tollerance

then checking again with feeler gauge

Third, second and reverse gears (and bushes and synchro rings) refitted to the mainshaft and checking endfloat in first gear bush here (large brass bit at top of shaft)

first gear (new one) now refitted (far right) and so mainshaft re-assembly now complete

modification made to peg the rear bearing housing to prevent it from spinning in the casing - a common fault which had been happening with this example as well

bearing pressed into carrier and retained with locking compound

reverse idler assembly with replacement idler shaft and needle rolling bearing below

mainshaft rear bearing and housing, idler shaft, and layshaft rear bearing outer - all in with the mince in the freezer...

gearbox casing on the woodstove (good job it was a grey day in may and we had the fire on)...

... which enabled the fozen components to be gently tapped into the expanded gearbox case as seen here

trial fitting the layshaft alongside the reverse gear assembly

New layshaft and pinion bearings pressed (tapped) into the bellhousing

pinion fitted

layshaft trial fitted to measure endfloat

mainshaft and layshaft now fitted to box

tight fit

oil seal, thrower, nut fitted to rear end of mainshaft

oil seals and gaskets following the new bearings

bellhousing complete and ready for clutch arm later

selector rods assembled with new seals and a new fork for 1st/2nd selector

in place