519 Gearbox Rebuild

[58A - 71E]

Had already started assembling some other bits including the front supports and put in the breather mushroom







And then used new split axle boots once the axle tubes were on



Here is one of my old rear mounts, knackered! Certainly wont have helped with shifting in gear and probably why the engine tin wasn’t lining up properly before!



And compared to the new ones



Now to finish putting all the other bits on!

[Schläfer]

What a stunning write up. This has got to be a sticky!

Well done James!

[hot66]

Superb thread James

I assume the rebuild only took a couple of hours after work one night ???

[58A - 71E]

Thanks LGK 6D, hope someone finds my experience helpful

I assume the rebuild only took a couple of hours after work one night ???

Oh yeah
I'm probably into it in total about 50 hours, and more again today

[58A - 71E]

Realised during the week that I had one bit left over , PET calls it a ‘baffle plate’, here it is



I couldn’t work out where it went so I took the opportunity at yesterday’s day out at Andy Prill’s place to ask Max the gearbox expert where it should go. Well just my luck, if it had been a tunnel type gearbox I could have dropped off a half shaft and put it in place, but because this is a split case gearbox it meant I would have to split it again. Oh how I laughed. So today I undid a load of my work and split the case again.
It sits here in the right case half



So had to clean all the case sealer off and redo it all again.

[58A - 71E]

Just as I came to assemble reverse gear I accidentally pulled the selector rod too hard and pulled it out of the case and heard the spring loaded detent ball roll around inside.

Laugh, well no actually the air was so blue the next door neighbour asked if everything was alright. So split the case AGAIN, clean the sealer and start again. Anyway, here’s the offending securing bolt in place where previously a hole was that I really should have noticed before.



So today at least taught me that you have to be dead careful when moving the selector rods cos otherwise you can pull them out, and if there’s a bit left over in a rebuild its never a good sign!
So for anyone else contemplating doing this, but the baffle plate in before sealing up the case halves!

[Mike Smith]

James,

just a note to say what a pleasure it is to see someone, working clean, taking the time to learn and doing the job properly - I have 3 x Boxes waiting for you when you`ve finished that one

You will have to coat that lovely clean finish you have with some sort of protection, otherwise it will corrode in no time - Tectyl is good - send me an address and you get a free can

[roy mawbey]

James,

I have studied every photo and every sequence, that alone has just taken me about 45 minutes!! You are a hero especially as no doubt you had to wash your hands every time you took a photo! and they are really good quality photos!!

I have never taken my later 716 apart ( touch wood ) no doubt it would make me think first now. I have done other boxes before but not to the same standard as you.

Yes, that should become a sticky it's that useful. Sure I have the Elfrink book and the factory manual but those photos tell you a lot more than any book!

Really well done and a great presentation. Can't wait to hear if it changes smoothly!

Tools are everything never attempt anything like that unless you have the tools and know how to use them!!!

I love tools!!

Roy

[58A - 71E]

Thanks for the kind words Mike and your generous offer - a tin of tectyl eh - its like the oscars but winning something far more useful, thankyou

Roy, time will tell if it changes smoothly, I've just got the small job of getting the car back together to test it, so probably gonna be one for 2010 hopefully I wont be doing another strip down then oh and tools you say, oh yes, a man can never have too many tools, but as said earlier, I really do owe DDK'r John Fletcher the credit for that one, the 'gauge' he leant me was the crucial bit

[john fletcher]

James
Now I'm back from my hols. I've had a closer look at your presentation and its fantastic! There ought to be a Tech. Library on DDK to access this sort of work for future reference by everyone - a bit like the US 356 Registry.
Maybe your efforts with the g/box will encourage others to send in details of their work as well.
There is usually someone out there struggling with the same problems and all it needs is to share the information and we can all benefit.

John

[TheBaron]

Just one word will sum up what you have done, Awesome.

Thanks, this will make for a great reference point for all DDKers brave enough to attempt what you have done.

Stephen

[CPC69]

What an awesome sequence of steps and tips for a 519 rebuild!

Its immensely helpful as I'm about to rebuild a 519 transmission for my pre-A, only issue is my transmission is in a box full of parts rather that arriving pre-built...wish me luck!

I'll post pictures when (if) I'm successful.

One thing, I've noticed that I'm missing the steel intermediate plate. Does anyone know where I will get one from or have one for sale please???

[neilbardsley]

Bravo sir. I hope I never have to do this!

Sent from my X5pro using Tapatalk

[sladey]

I missed this write-up 7 and a half years ago - fantastic stuff and (belated) thanks for sharing it. The more I look at gearboxes the more fascinating I find them - such a brilliantly mechanical thing

[Phil Parry]

I missed it too. James, it's superb and so useful and I really felt your frustration as you needed to split the case yet again.