Welcome to Somerford Mini Ltd.

Using This Catalogue

Somerford Mini Limited was established in 1990 by Peter Hines, a Mini enthusiast. The Illustrations and Illustration Numbers: The illustrations are carefully
company has been very successful and now boasts a huge spares department alongside crafted to guide you to the parts you want for your car. Each assembly is depicted
the original restoration business. Manned by restorers with a deep passion for (and vast in an exploded format and for consistency, where practicality permits, the view is from
knowledge and experience of) the Mini, our workshop enjoys a reputation as one of the a left hand front three quarter angle (we’re also aware that many customers use
country’s leading Mini restoration centres. With the spares and restoration departments catalogues as a visual guide to the assembly procedure of their car!). If only one hand
together as a team, we have the full blessing of MG Rover, through being a British Motor is illustrated of a part with right and left hand versions, both hands will be listed under
Heritage Approved Specialist. We are justifiably proud of this accolade. the matching illustration number in the text, usually with the right hand listed first.

The spares side of the business started in 1994 and has grown at an incredible rate. We Part Number: A part number is the identifying name for a part in our stock
now stock over 8000 lines, with more being added all the time. We cater for all Minis, control system, and differentiates between versions – right hand or left hand, early or
from 1959 to the end of production in 2000, with the parts needed to carry out a full late model. We ask you, where you can, to use part numbers when ordering – it helps
restoration, including very specialised body fittings that are not otherwise widely to guarantee you get the exact parts you need. If you can’t work out which part
available. Other stock ranges from service items right the way through to accessories, number or you’re having difficulty working out exactly what it is you need, please
performance parts and all the latest gizmos to dress up your Mini. contact us. We are only too happy to guide you or work it out for you.

Somerford Mini Limited is still a small enough company to guarantee a personal service, Description: We need to clarify here what we mean by right and left hand. Right
a very important consideration. Unlike many of our competitors, we can offer proper and left hand is always taken from a viewpoint of sitting in the car, not from standing
advice before you make your purchase. We know from our own workshop experience in front of it. So why don’t we say ‘offside’ or ‘nearside’? Because offside for a right
what works and what doesn’t, so if you’re not sure about something please ask – the hand drive car is nearside for a left hand drive car (you can see how this becomes
chances are we can help. Our workshop is also able to fit any part we sell, if you so easily confused…).
choose. We take a pride in being totally honest with our customers and not making
false promises (tales of which you hear only too often with some mail order companies). Quantity Required: This is always the quantity required per car. For example,
if two bolts hold a hinge, and there are four hinges on the car, the quantity required
We look forward to helping you to care for your cherished Mini. will be shown as 8, not 2.

Peter Hines Remarks: This is additional descriptive information to help you identify the part
Somerford Mini Limited. you need, to tell you exactly what you’ll receive if you order that part, or to make you
aware of an available alternative. It does this by telling you to which models or in
which years a part was originally fitted (if there is a choice), or what that part includes,
or whether that part can be used on other models.
Ordering Parts
When ordering parts, it is very helpful if you also provide us with information about Parts Availability
your car. Details such as the chassis number (or vehicle identification number on While the great majority of the parts listed in this catalogue are currently available,
later models), engine number, year of manufacture, whether the car is right or left there are some that are not. A few of the parts shown in this catalogue are there in
hand drive and details of any modifications will all help to ensure you get the parts anticipation of what may become available in future (new or reintroduced products are
you need. constantly under development). A handful of others are there to historically acknowledge
what would have originally been fitted and are, where possible, accompanied by an
You can order parts by telephone, fax, mail, e-mail, through our website, or alternative, serviceable product. It therefore follows that this catalogue does not
alternatively you would be most welcome to visit our shop during normal trading constitute a definite offer for sale of any particular item.
hours (Monday to Friday 9.00am to 6.00pm, Saturday 9.00am to 2.00pm, Sunday
closed). We provide a range of methods of despatch for your order, from regular In the accompanying price list, a price beside the part number indicates that the part
post through to next day courier delivery. Sometimes the method of despatch is is usually available; if the part number is absent it indicates non-availability. If the
dependant on the weight or size of your order. We are of course happy to give you comment ‘use’ (followed by a different part number) is found, the original part has been
a quotation, including delivery costs, before you place your order with us. superseded by an available alternative.

Overseas customers should note that sometimes shipments will be subject to local
import duties, which are not included in the price we charge for your order, or the Copyright
delivery costs. These duties must be paid by you before you can receive your Copyright Somerford Mini Limited October 2006. All rights reserved. No part of this
shipment. Value Added Tax at the current United Kingdom rate will be levied on all publication may be reproduced, stored in a retrieval system, or transmitted in any form
orders despatched to countries within the European Community, but will not be by any means, electronic, photocopying, recording or otherwise without prior written
levied on orders despatched to the rest of the world. consent of Somerford Mini Limited.

We accept payments for orders by cash, personal cheque, bank draft, Sterling
travellers cheque and most credit or debit cards, including Visa, Mastercard, Maestro
British Motor Heritage Approval
(Switch) and Delta. If you intend to pay by personal cheque or bankers draft, we Somerford Mini Limited is a British Motor Heritage approved specialist. Our agreement
would advise you to ask for a parts availability check and quotation before placing with British Motor Heritage permits the use of certain marque logos and some of the
your order. artwork contained in this catalogue. The remainder of the artwork is the intellectual
property of Somerford Mini Limited.
Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Change Points better town car, which in some other respects it undoubtedly is. Also, refinement is not
the automatic’s greatest feature; it changes gear rather a lot (often downwards),
In the catalogue you will see parts changes referred to by dates. We have steered away subjecting the car’s occupants to even more noise than in a manual Mini.
from the tradition of listing change points by chassis or commission number (they’re
different, and the factory parts books used both) because they are so complicated on It is surprising that the innovative and promising Mini automatic was largely starved of
Minis. All the models had different change points until 1984 (after which it got much development during its 35 years in production, major changes being confined to the the
easier) and to list change point numbers often amounts to half a page of text! gearchange mechanism, plus the introduction of A Plus drop gears in 1982.

As a result, we’ve used years instead. While much more simple, we acknowledge that Opinions concerning Minis fitted with automatic transmission entrench the enthusiast
using dates to portray change points is not perfect. For example, you will know the fraternity, the vast majority believing that the only good thing you can do with an
year of registration of your car but you might not know the year of manufacture - the automatic Mini is to convert it to manual. Yet the automatic Mini still does have its
two aren’t necessarily the same. Also, a revised part was often introduced during a year supporters, not least in Japan, the Mini’s biggest market in the 1990s, where nearly all
rather than at the beginning or end of it. If you have difficulty in establishing which of the Minis sold were automatics because of that country’s highly congested city roads.
part is for your car, you will find a list of Mini models production history at the end
of this catalogue which may help. If it doesn’t, contact us, preferably with your chassis,
commission or engine number to hand, and we’ll do our best to sort it out for you. Contact Us
Somerford Mini Limited
Unit 2 Broadfield Farm,
Mini Transmissions Great Somerford, Chippenham, Wiltshire, SN15 5EL
e-mail [email protected]
The manual gearbox created for the Mini in 1959 was an essential factor in the Tel. 01249 721421 Fax. 01249 721316
amazing space efficiency of the car. Developed from the gearbox used by BMC’s other
A Series-engined cars of the time like the Morris Minor (and sharing many of the
gearbox internals), the Mini gearbox was the first to be positioned under the engine. Opening Times
This allowed the entire power unit to be mounted transversely in the car, keeping the Monday to Friday: 9.00am to 6.00pm
area occupied by it to a bare minimum. Saturday: 9.00am to 2.00pm Sunday: Closed

Gear selection was made by a long gear lever (‘direct change’), remembered affectionately
as the ‘magic wand’ or ‘pudding stirrer’ by those who owned early Minis. Power was
transferred from the engine and clutch down to the gearbox via a series of three gears Contents
colloquially referred to as the drop gears; the design initially allowed oil onto the clutch
all too frequently, causing severe slippage. The sealing system had to be quickly Manual Gearbox - Flywheel and Clutch 2
redesigned and a programme was carried out to modify the Minis built thus far.
Manual Gearbox - Flywheel Housing and Clutch Cover 4
After this hiccup the Mini gearbox settled down to a reasonably trustworthy existance.
It was, however, still subjected to many improvements through the years and apart from Manual Gearbox - Clutch Pedal and Hydraulics 6
the basic shape of the gearbox case very little of the 1990s Mini gearbox is recognisably
the same as that on early cars. Manual Gearbox - Primary, Idler and 1st Motion Shaft Drive Gears 8

Most of the modifications centred on improving the gearchange - a remote gearchange Manual Gearbox - External Components 10
arrived in 1961 (for several years fitted only to Coopers, it had the additional benefit
of considerably steadying engine movement), cone synchromesh gave way to baulk rings Manual Gearbox - 3 Synchromesh Internal Components 12
in 1962, a proper synchromesh gear replaced the old ‘crash’ first gear in 1968 and the
remote gearchange plus the gear selectors were replaced by a system known as ‘rod Manual Gearbox - 4 Synchromesh Internal Components 16
change’ in 1973.
Manual Gearbox - Selectors and Speedometer Drives 18
Two other major design modifications are worthy of note, both involving quietening the
gearbox. Around 1963-64 the angle of the gear teeth was changed (post-modification Manual Gearbox - Direct and Remote Gearchanges 20
gears being known as B Type and pre-modification retrospectively becoming A Type).
This happened again around 1982 (the new gears being known as A Plus), bringing the Manual Gearbox - Rod Gearchange 22
Mini gearbox in line production-wise with the recently introduced Austin Metro. Exact
identification of a Mini manual gearbox prior to replacement of gears is therefore of Automatic Transmission - Torque Converter and Housing 24
paramount importance - different angled gear teeth will not mesh together!
Automatic Transmission - Transmission Components 26
Automatic transmission arrived in the Mini for 1965. A special automatic specification
engine block had to be cast, a fact not lost on Mini owners who have converted their Automatic Transmission - Gearchange Controls 28
cars from automatic to manual and had to change the engine as well as the gearbox.
Final Drive (Differential) 30
The Mini automatic has significantly worse fuel economy as well as poorer acceleration
than that managed by manual Minis, detracting from the automatic’s claim to be the Mini Production History 32

Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk 1

Manual Gearbox - Flywheel and Clutch

2 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - Flywheel and Clutch
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Flywheels with the 1 3/8" machining for the Deva bush) will accept a diaphragm type clutch plate, but not a
diaphragm housing. 1959-62 oil-fed bush type flywheels (can’t be many of these left now, surely - most
Coil Spring and Diaphragm Spring Clutch Types, 1959-82
were replaced with Deva flywheels in the 1960s) will only accept coil spring clutch components. If you’re
1 22A129 FLYWHEEL ASS’Y, two piece, oil-fed 1 1959-62; coil spring clutch. Replaces
unlucky enough to need to replace the clutch on one of these, a crankshaft, primary gear and flywheel
bush type DU bush flywheel on earliest cars.
swap will be required - or an engine swap, which might be cheaper and would certainly be quicker.
22A443 FLYWHEEL ASS’Y, two piece, Deva metal 1 1962-63; 1 3/8" dia. Deva bush
bush type machining and coil spring clutch.
Please contact us if you require replacement parts for a coil spring clutch assembly, giving us if possible
12G3014 FLYWHEEL ASS’Y, one piece, Deva metal 1 1963-82; 1 1/2" dia. Deva bush
as much detail as you can about the dimensions of the flywheel to which the clutch is to be fitted. The
bush type machining, coil or diaphragm clutch.
following are the original components for coil spring clutches:
Originally there were several 1963 on two piece flywheel designs (i.e. the flywheel was bolted to a
18 2A3509 PLATE, pressure 1 Not Cooper models.
separate hub); all are now replaced by the later one piece flywheel.
22A539 PLATE, pressure 1 997 and 998 Cooper, 1071 Cooper S.
19 88G541 PLATE, driven 1
C-AEG619 FLYWHEEL ASS’Y, lightened steel type 1 For fast road and competition use.
20 22A214 SEAL, oil, small 1 For 1959-62 models with oil-fed bush
2 12G676 RING GEAR, starter motor, 1/2" wide 1 Included in standard flywheel ass’ys.
type flywheels.
22G2613 RING GEAR, starter motor, 11/32" wide 1 Included in C-AEG619 lightened
21 2A3658 STRAP, driving 12
flywheel assembly.
22 2A3659 SCREW, strap 3
22A130 GASKET, hub to flywheel 1 1959-62; included in oil-fed bush
23 2A3512 LOCK TAB, strap 3 Included in 18G8086 clutch lock tab kit.
flywheel assembly.
24 PWZ106 WASHER, plain 3
3 22A56 SCREW, hub to flywheel 6 Included in two piece flywheel ass’ys.
25 22A87 HOUSING, coil pressure springs 1 Does not include springs.
4 LWZ606 WASHER, shakeproof 6 Included in two piece flywheel ass’ys.
26 2A3657 SCREW, housing to pressure plate 3
5 FNZ506 NUT 6 Included in two piece flywheel ass’ys.
27 LWZ606 WASHER, shakeproof 3
6 22A325 OIL SEAL, Nu-lip type 1 1959-61; for DU bush type flywheel.
28 22A6 SPRING, pressure 6 Not Cooper models.
22A214 OIL SEAL, small 1 1961-62; for oil-fed bush type flywheel.
22A275 SPRING, pressure, black with white spot 6 997 and 998 Cooper, 1071 Cooper S.
7 2A3530 SCREW, flywheel to crankshaft 1 1959-63.
colour coded
22A747 SCREW, flywheel to crankshaft 1 1963-82.
29 2A3651 FLANGE, clutch release 1
8 22A1155 LOCKTAB, flywheel screw 1 Included in 18G8086 clutch lock tab kit.
30 22A8 BOLT, housing to flange 3
9 88G508 KEY, flywheel to crankshaft 1
31 FNZ505 NUT 3
32 51K1261 LOCK TAB, nut 3
Verto Clutch Types, 1982 On
33 GRB201 BEARING, clutch release 1
The Verto flywheel and clutch assembly was introduced as a means of lightening the effort required to
34 18G8086 LOCK TAB KIT, clutch 1 Includes lock tabs for strap and
operate the clutch (the older diaphragm clutch was a very strong and reliable design which
flywheel securing screws, plus lock tabs
unfortunately required an agricultural stomp of the foot, quite unbecoming in a new car by the 1980s,
for spring housing screws.
to operate it).
Diaphragm Clutch, 1964-82
As replacement parts, Verto clutches were originally only supplied as balanced assemblies complete with
35 22A598 PLATE, pressure 1 Standard fitment; not Cooper models.
flywheel, in an attempt to counter clutch judder in service. Nowadays, you can purchase the clutch
22G270 PLATE, pressure 1 Standard fitment; Cooper and Cooper S.
components separately if you wish, but the flywheel is still only available as part of the (rather steeply
C-AHT230 PLATE, pressure 1 Lightweight; for fast road and
priced) flywheel and clutch assembly.
competition use.
10 GCU90107AF FLYWHEEL AND CLUTCH ASS’Y, balanced 1 1982-85; for inertia starter fitted
36 GCP204AF PLATE, driven 1 Standard fitment - road use.
998cc models.
C-AHT596 PLATE, driven 1 Uprated fitment - fast road or
GCU90115AF FLYWHEEL AND CLUTCH ASS’Y, balanced 1 1985-90; for pre-engaged starter
competition use.
fitted 998cc models.
C-AHT598 PLATE, driven, sintered paddle type 1 Uprated fitment - competition use.
GCU90122AF FLYWHEEL AND CLUTCH ASS’Y, balanced 1 1990-94; for 998cc and carburetter
37 2A3658 STRAP, driving 12
fitted 1275cc models.
38 2A3659 SCREW, strap 3
GCU90121AF FLYWHEEL AND CLUTCH ASS’Y, balanced 1 1991-96; for SPi (single point
39 2A3512 LOCK TAB, strap 3 Included in 18G8086 clutch lock tab kit.
injection) fitted 1275cc models.
40 PWZ106 WASHER, plain 3
GCU90123AF FLYWHEEL AND CLUTCH ASS’Y, balanced 1 1997 on; for MPi (multi point
41 GCC103 HOUSING, with diaphragm spring 1 Standard fitment - road use.
injection) fitted 1275cc models
C-AEG481 HOUSING, with diaphragm spring, 1 Uprated fitment - fast road or
plus SPi (Japan).
orange coded competition use.
11 12G2445 RING GEAR, 107 teeth 1 1982-85; included in inertia starter
C-AEG482 HOUSING, with diaphragm spring, 1 Uprated fitment - competition use.
flywheel assemblies.
grey coded
PSF10003 RING GEAR, 129 teeth 1 1985 on; included in pre-engaged
42 AAU7154 PLATE, release 1 Included in housing.
starter flywheel assemblies.
43 22A921 CIRCLIP, plate 1 Included in housing.
12 DAM5922 BOLT, locking, flywheel to crankshaft 1
44 2A3657 SCREW, housing to pressure plate 3
13 DAM5923 KEY, flywheel to crankshaft 1
45 LWZ406 WASHER, shakeproof 3
46 GRB201 BEARING, clutch release 1
Clutch Kits 47 18G8086 LOCK TAB KIT, clutch 1 Includes lock tabs for strap and
14 - CLUTCH KIT, three piece, coil spring type 1 1959-64; kit not available - purchase flywheel securing screws.
parts separately.
15 GCK100AF CLUTCH KIT, three piece, diaphragm type 1 1964-82. Verto Clutch, 1982 On
16 GCK149AF CLUTCH KIT, five piece, Verto type 1 1982-90; with 184mm diameter 48 GCP271AF PLATE, driven 1 1982-90; 184mm diameter clutch.
clutch plate. GCP90832AF PLATE, driven 1 1990 on; 190mm diameter clutch.
17 MHK51141 CLUTCH KIT, five piece, Verto type 1 1990 on; with 190mm diameter 49 GCC679 DIAPHRAGM AND PRESSURE PLATE ASS’Y 1 1982-90; 184mm diameter clutch.
clutch plate. C1644AF DIAPHRAGM AND PRESSURE PLATE ASS’Y 1 1990 on; 190mm diameter clutch.
QKT313AF CLUTCH KIT, five piece, Verto type 1 Heavy duty; for use with Metro Turbo 50 BAU2319 BOLT, diaphragm and pressure plate 3
power unit. securing
51 BAU2320 WASHER, shakeproof 3
Clutch Components 52 WAM1188 RELUCTOR RING, engine management 1 Injection models only; included in
flywheel and clutch assembly.
Coil Spring Clutch, 1959-64
53 SJ104121M SCREW, reluctor ring to flywheel 2
At time of writing, components for the coil spring clutch fitted between 1959 and 1964 are hard to
54 AHU1564 SLEEVE, clutch release 1
come by, to say the least. The later design diaphragm housing and/or clutch plate can be used to
55 GRB239 BEARING ASSEMBLY, clutch release 1
repair or replace a coil spring clutch in some instances: however by rule of thumb, the earlier the
56 AAU2866 O RING, clutch release bearing 1
flywheel and crankshaft, the less likely this will be possible. On 1963-64 flywheels, it’s a straight
replacement of coil spring clutch parts by diaphragm clutch equivalents. 1962-63 flywheels (i.e. those

Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk 3

Manual Gearbox - Flywheel Housing and Clutch Cover

4 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - Flywheel Housing and Clutch Cover
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Flywheel Housing 22 22A1299 PLATE, dowel retaining 1 1968 on (4 synchro gearbox).

1 22G999 FLYWHEEL HOUSING, no breather hole 1 1959-68, 3 synchro gearbox, all models.
For certain markets or on certain models during the 1960s, the starter solenoid was fixed to a bracket
DAM3165 FLYWHEEL HOUSING, no breather hole 1 1968-69, 4 synchro gearbox, all models.
attached to the flywheel housing:
1969-79, 4 synchro gearbox, not
23 12A369 BRACKET, starter solenoid to flywheel 1 Not Cooper S models.
1275cc.
housing
DAM6259 FLYWHEEL HOUSING, no breather hole 1 1979-92, 4 synchro gearbox, not
12G326 BRACKET, starter solenoid to flywheel 1 Cooper S models.
1275cc.
housing
2 DAM3161 FLYWHEEL HOUSING, with breather hole 1 1969-79, 4 synchro gearbox, 1275cc.
24 SH505051 SCREW, bracket to flywheel housing 2
DAM6257 FLYWHEEL HOUSING, with breather hole 1 1979-91, 4 synchro gearbox, 1275cc
25 LWZ305 WASHER, locking 2
carburetter.
TRD10015 FLYWHEEL HOUSING, with breather hole 1 1991 on, 4 synchro gearbox, 1275
and crank sensor hole injection and carburetter. Clutch Cover and Clutch Release Mechanism
3 88G302 BEARING, idler gear (1.004" ext. dia.) 1 1959-68, 3 synchro gearbox. 1959-82, Coil Spring or Diaphragm Clutch
13H7848 BEARING, idler gear (1 1/16" ext. dia., 1 1968-79, 4 synchro gearbox. 26 88G300 COVER, clutch, with timing hole 1
3/4" int. dia.) 27 2A3635 COVER, timing hole 1
AHU1707 BEARING, idler gear (1 3/8" ext. dia., 1 1979 on, 4 synchro gearbox. 28 SH604041 SCREW, timing hole cover to clutch cover 2
7/8" int. dia.) 29 LWZ304 WASHER, locking 2
DAM3745 BEARING, idler gear, special, with sleeve 1 For use, see note below. 30 53K146 SCREW, clutch cover to flywheel housing 8
(1 3/8" ext. dia., 3/4" int. dia.) DAM7755 BOLT, flanged head, clutch cover to 8
4 LCG10001 BLANKING PLATE, crank sensor hole 1 1992-94, 1275 carburetter. flywheel housing
5 FS105101 SCREW, blanking plate to 2 1992-94, 1275 carburetter. 31 LWZ305 WASHER, locking 8
flywheel housing 32 22A180 PLUNGER, clutch release 1 Release bearing secures by press-fit.
33 DAM1955 PLUNGER, clutch release 1 Alternative; release bearing secures
Interchangeability of flywheel housings: with clip.
For 1959-68 models (3 synchro gearbox), none of the later 4 synchro flywheel housings can be used in 34 DAM2413 CLIP, release bearing to plunger 1 Use with DAM1955 plunger.
place of the original. 35 22A427 NUT, clutch release stop 1
36 NT610041 NUT, locking clutch release stop nut 1
For 1968-79 models (not 1275), flywheel housing DAM6259 may be used, so long as the special idler The very earliest cars from 1959-60 were originally fitted with a plunger with an integral (non-
bearing with sleeve DAM3745 is also fitted. adjustable) stop. This may be replaced by either of the plungers listed above, together with a 22A427
stop nut and NT610041 lock nut.
For 1968-69 models (1275 only), flywheel housing DAM6259 may be used, so long as the special idler
bearing with sleeve DAM3745 is also fitted. 37 22A2204 LEVER, clutch release 1
38 CLZ628 CLEVIS PIN, lever pivot in clutch cover 1
For 1969-79 models (1275 only), flywheel housing DAM6257 may be used, so long as the special idler 39 PWZ106 WASHER, plain 1
bearing with sleeve DAM3745 is also fitted. Alternatively, flywheel housing TRD10015 may be used, so 40 ZPS307 SPLIT PIN 1
long as LCG10001 crank sensor hole blanking plate and two off FS105101 screws are also fitted, along 41 SH604091 SCREW, lever adjusting 1
with the special idler bearing and sleeve DAM3745. 42 FNZ604 NUT, locking adjusting screw 1
43 CLZ518 CLEVIS PIN, lever to slave cylinder 1
For 1979-91 models (1275 carburetter), flywheel housing TRD10015 may be used, so long as LCG10001 push rod
crank sensor hole blanking plate and two off FS105101 screws are also fitted. 44 PWZ105 WASHER, plain 1
45 ZPS306 SPLIT PIN 1
These notes show how to use later (therefore hopefully still available) flywheel housings on earlier 4 46 1G5999 SPRING, clutch release lever 1
synchro power units. They rely on the original idler gear being retained... if you’re not sure what’s 47 2A3601 ANCHOR, spring, clutch release lever end 1
original on the car for its year, to be safe you may have to dust off a vernier caliper and deduce (i) 48 2A3600 ANCHOR, spring, slave cylinder end 1
the external diameter of the idler gear bearing required (measure the bearing location in the flywheel
housing) and (ii) the internal diameter required (measure the idler gear shaft diameter). Having done 1982 On, Verto Clutch
so, you should be able to find a bearing size above to suit your purposes. 49 AHU1068 COVER, clutch, with timing hole 1 1982-85; with inertia starter.
AHU1106 COVER, clutch, without timing hole 1 1985 on; with pre-engaged starter.
6 13H2934 OIL SEAL, clutch (primary gear oil seal) 1 All carburetter models. 50 2A3635 COVER, timing hole 1 1982-85.
LUF10005 OIL SEAL, clutch (primary gear oil seal) 1 All injection models. 51 SH604041 SCREW, timing hole cover to clutch cover 2 1982-85.
7 DAM2821 SHIELD, oil seal protection 1 1982 on; all Verto clutch models. 52 LWZ304 WASHER, locking 2 1982-85.
8 AAU8424 BEARING, first motion shaft 1 53 53K146 SCREW, clutch cover to flywheel housing 7
9 2A3643 CIRCLIP, bearing to flywheel housing 1 DAM7755 BOLT, flanged head, clutch cover to 7
10 CCN110 CIRCLIP, bearing to first motion shaft 1 flywheel housing
11 GUG705563GM GASKET, flywheel housing to cylinder 1 54 LWZ305 WASHER, locking 7
block/gearbox The eighth screw used to secure a Verto clutch cover is the long screw securing the slave cylinder bracket
12 18G8086 LOCK TAB KIT, clutch 1 Includes lock tabs for strap and (please see Clutch Pedal and Hydraulics section).
flywheel securing screws, plus lock
tabs for flywheel housing screws. 55 DAM5353 PLUNGER, clutch release 1
13 22A1762 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit. 56 AAU2866 O RING, release bearing 1
14 22A1761 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit. 57 22A427 NUT, clutch release stop 1
15 2A3521 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit. 58 NT610041 NUT, locking clutch release stop nut 1
16 22A1241 LOCK TAB, flywheel housing attachment 1 1968 on (4 synchro gearbox); 59 DAM5355 LEVER, clutch release 1
included in clutch lock tab kit. 60 CLZ628 CLEVIS PIN, lever pivot in clutch cover 1
17 BH605141 BOLT, long, flywheel housing attachment 3 61 PWZ106 WASHER, plain 1
DAM7758 BOLT, flanged, long, flywheel housing 3 Alternative. 62 ZPS307 SPLIT PIN 1
attachment 63 SH604091 SCREW, lever adjusting 1
18 LWZ305 WASHER, locking 3 64 FNZ604 NUT, locking adjusting screw 1
19 SH605081 SCREW, short, flywheel housing 3 65 CLZ518 CLEVIS PIN, lever to slave cylinder 1
attachment push rod
DAM7753 BOLT, flanged, short, flywheel housing 3 Alternative. 66 PWZ105 WASHER, plain 1
attachment 67 ZPS306 SPLIT PIN 1
20 FNZ505 NUT, flywheel housing attachment 9
21 LWZ305 WASHER, locking 4

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Manual Gearbox - Clutch Pedal and Hydraulics

6 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - Clutch Pedal and Hydraulics
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Clutch Pedal and Pedal Box 25 GRK3004 REPAIR KIT, later metal or plastic tank 1 For cylinders with two ring seals (see
master cylinders note).
1 2A5866 CLUTCH PEDAL ASSEMBLY 1 1959-75.
26 27H7751 SPRING, return 1
2 NAM3116 CLUTCH PEDAL ASSEMBLY 1 1976 on, RHD.
27 17H7560 CIRCLIP 1
NAM3115 CLUTCH PEDAL ASSEMBLY 1 1976 on; LHD.
28 17H7557 PUSH ROD 1
3 2A3034 BUSH, clutch pedal 1 Included in clutch pedal assembly.
29 17H7555 ADAPTOR, cylinder to clutch pipe 1 Very early original cylinders only.
4 GPR104 PAD, clutch pedal 1 1959-75.
30 17H7556 SEAL, adaptor 1 Very early original cylinders only.
5 GPR107 PAD, clutch pedal 1 1976-90.
SZU10001 PAD, clutch pedal 1 1990 on.
6 2A5880 SHAFT, clutch and brake pedals 1 RHD, all models; 1959-88, LHD Clutch Pipe and Hose
without direct acting brake servo. Clutch Pipe
NAM8524 SHAFT, clutch and brake pedals 1 1988 on, LHD with direct acting Pre-assembled clutch pipes can be supplied in Cunifer, a superior material which bends to shape easily,
brake servo. doen’t work harden and subsequently split and does not corrode. If desired, however, we will supply
7 LNZ205 NUT, nyloc 1 pipes in original Bundy material or copper - for either of these, please contact us.
8 2A5652 SPRING, clutch pedal return 1 1959-88, without direct acting brake 31 21A2234 CLUTCH PIPE ASSEMBLY, 28cm long 1 RHD models.
servo. 21A70 CLUTCH PIPE ASSEMBLY, 86cm long 1 LHD models.
NAM8544 SPRING, clutch pedal return 1 1988 on, RHD with direct acting
brake servo. If you have flaring and pipe bending tools to hand, individual components to make up your own clutch
NAM8547 SPRING, clutch pedal return 1 1988 on, LHD with direct acting pipe are also available:
brake servo. 32 CNF316 CLUTCH PIPE, superior cunifer material, A/R Will require cutting and flaring to fit.
9 2A5859 PEDAL BOX ASSEMBLY 1 1959-71, single line brakes. per metre
21A2467 PEDAL BOX ASSEMBLY 1 1971-75, single line brakes. HCP316 CLUTCH PIPE, copper material, per metre A/R Will require cutting and flaring to fit.
21A2056 PEDAL BOX ASSEMBLY 1 1969-71, dual line brakes. 33 TM606031 TUBE NUT, brake pipe union, 3/8 UNF, A/R
21A2345 PEDAL BOX ASSEMBLY 1 1971-75, dual line brakes. male
NAM8670 PEDAL BOX ASSEMBLY 1 1976-88, dual line brakes without 34 21A64 CLIP, pipes to dash 2 LHD with single line brakes.
direct acting servo. 35 FNZ103 NUT, clip to dash 2 LHD with single line brakes.
SKU10043 PEDAL BOX ASSEMBLY 1 1988-96, RHD with direct acting 36 WL700101 WASHER, locking 2 LHD with single line brakes.
servo. 37 6K751 SLEEVE, rubber, clutch pipe 2 LHD with single line brakes.
SKU101220 PEDAL BOX ASSEMBLY 1 1997 on, RHD, all models. 38 21A2192 CLIP, pipes to dash 2 LHD with front/rear split brakes.
SKU10040 PEDAL BOX ASSEMBLY 1 1988-94, LHD carburetter models. 39 FNZ103 NUT, clip to dash 2 LHD with front/rear split brakes.
SKU10042 PEDAL BOX ASSEMBLY 1 1991-96, LHD injection models. 40 WL700101 WASHER, locking 2 LHD with front/rear split brakes.
SKU101210 PEDAL BOX ASSEMBLY 1 1997 on, LHD, all models. 41 CAC402 CLIP, double, pipes to dash 2 LHD with diagonally split brakes.
10 21A2348 CLAMP, pedal box 1 1971-75, dual line brakes.
11 21A1657 PLATE, locating 1 1959-75, models fitted with steering Clutch Hose
lock. 42 GVP1020 CLUTCH HOSE, rubber 1 1959-82; standard fitment. Coil spring
12 SH605051 SCREW, pedal box to body 2 and diaphragm clutches.
13 LWZ205 WASHER, locking 2 43 BHS001 CLUTCH HOSE, stainless braided 1 1959-82; uprated fitment. Coil spring
14 CLZ512 CLEVIS PIN, pedal to master cylinder 1 and diaphragm clutches.
push rod 44 GVP1009 CLUTCH HOSE AND BANJO UNION, rubber 1 1982 on; standard fitment. Verto
15 GHF502 SPLIT PIN 1 clutch.
16 RCLIP01 ‘R’ CLIP 1 MUCH easier to fit than a split pin! 45 BHS002 CLUTCH HOSE AND BANJO UNION, 1 1982 on; uprated fitment. Verto
Fitting the split pins to the top of the clutch and brake pedals to connect them to their respective stainless braided clutch.
master cylinder push rods is one of those classically frustrating jobs on a Mini - you know the score: a 46 2K8686 NUT, clutch hose to dash crossmember 1
half minute job that takes half an hour because there’s so little space in which to manoeuvre! You can 47 LWZ510 WASHER, shakeproof 1
see where the split pin goes until you get your hand and a pair of pliers in there, after which you 48 233220A WASHER, sealing, hose to slave cylinder 1 1959-82.
can’t see what you’re doing and there’s no space to turn over the ends of the split pin anyway. An ‘R’ 49 C5192A BOLT, banjo, hose to slave cylinder 1 1982 on.
clip however can be inserted in place of the split pin, on the end of a pair of thin-nosed (‘snipe-nosed’) 50 3H550 WASHER, sealing, banjo bolt to banjo 1 1982 on.
pliers, and simply clips in place without a struggle. This is positively the easiest and most gratifying 51 233220A WASHER, sealing, banjo to slave cylinder 1 1982 on.
modification you’ll ever make to your Mini!
Slave Cylinder
17 31G279 GASKET, master cylinder to pedal box 1
Coil Spring or Diaphragm Clutch, 1959-82
18 FNZ505 NUT, master cylinder to pedal box 2
52 GSY110 SLAVE CYLINDER ASSEMBLY, clutch 1
19 LWZ205 WASHER, locking 2
53 GRK4008 REPAIR KIT, slave cylinder 1
54 3H2428 BLEED NIPPLE 1 Included in slave cylinder assembly.
Clutch Master Cylinder 55 13H396 PUSH ROD, clutch operating 1
The vast majority of Minis used the same metal tank clutch master cylinder (which could have either of 56 SH506101 SCREW, coarse thread, cylinder to 2
two internal designs - watch out and carry on reading below if you need a repair kit). This was flywheel housing
superseded in 1998 approximately by a plastic tank version, which saw use until the end of Mini 57 LWZ206 WASHER, locking 2
production in 2000. While metal and plastic tank master cylinders are theoretically interchangeable,
most owners seem to stick with the style appropriate for their car. Verto Clutch, 1982 On
58 GSY118 SLAVE CYLINDER ASSEMBLY, clutch 1
Around 1977 the manufacturer of the metal tank master cylinder changed the design of the piston 59 GRK4001 REPAIR KIT, slave cylinder 1
inside to incorporate two ring seals instead of the previous one ring seal and one cap (or blind) seal. 60 3H2428 BLEED NIPPLE 1 Included in slave cylinder assembly.
Most - but not all - metal tank master cylinders available since that time are of the later design, which 61 13H396 PUSH ROD, clutch operating 1
may be identified by a circle or groove cut into the body of the cylinder. The very late-model plastic 62 DAM5992 BRACKET, cylinder to flywheel housing 1
tank master cylinder also uses the ‘two ring seal’ piston design. Be sure to identify which cylinder you 63 SH606081 SCREW, cylinder to bracket 2
have before ordering internal parts for it! 64 LWZ206 WASHER, locking 2
65 SH506081 SCREW, coarse thread, bracket to 2
20 AAU4969 MASTER CYLINDER ASSEMBLY, metal tank 1 1959-98 approx. flywheel housing
GMC901078 MASTER CYLINDER ASSEMBLY, plastic tank 1 1998 approx. on. 66 LWZ206 WASHER, locking 2
21 17H3723 CAP, reservoir, metal, with seal 1 1959-63 approx. 67 ADU7036 DISTANCE PIECE 1
22 501524 SEAL, metal cap 1 Included with cap. 68 SH604141 SCREW, bracket to distance piece and 1
23 513123A CAP, reservoir, plastic 1 1963 approx. on. clutch cover
24 GRK3007 REPAIR KIT, early metal tank master 1 For cylinders with ring seal and end 69 LWZ204 WASHER, locking 1
cylinder cap (see note).

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Manual Gearbox - Primary, Idler and 1st Motion Shaft Drive Gears

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 Manual Gearbox - Primary, Idler and 1st Motion Shaft Drive Gears
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Primary, Idler and 1st Motion Shaft Drive Gears Primary Gear Front Thrust Washers
Several different combinations of primary gear and bushes were used on the earliest Mini power units 848, 997, 998 and 1098 Engines, Except 848 Engines 1962-63
built between 1959 and 1963, following the abject failure of the first, the so-called ‘D.U.’ bush and oil 24 22A321 WASHER, thrust, primary gear, front 1 0.110-0.112" (2.79-2.84mm).
seal design (which allowed engine oil seepage onto the clutch all too frequently). As an interim 22A322 WASHER, thrust, primary gear, front 1 0.112-0.114" (2.84-2.89mm).
measure, a revised oil-fed bush system was fitted - in most cases when the car came in for the 22A323 WASHER, thrust, primary gear, front 1 0.114-0.116" (2.89-2.94mm).
inevitable clutch replacement - and after a couple of false starts the ‘Deva’ dry-lubricated bush became 22A324 WASHER, thrust, primary gear, front 1 0.116-0.118" (2.94-2.99mm).
the standard fitment. Each system necessitated a different engine crankshaft and flywheel, as well as 22A450 WASHER, thrust, primary gear, front 1 0.118-0.120" (2.99-3.04mm).
the primary gear and bushes. Extra care must be taken to select matching components for these early
designs. 848 Engines 1962-63
25 22A295 WASHER, thrust, primary gear, front 1 0.123-0.125" (3.12-3.17mm).
From 1963 onwards, crankshaft, flywheel, primary gear and bush combinations settled down into two 22A83 WASHER, thrust, primary gear, front 1 0.125-0.127" (3.17-3.22mm).
designs, depending on the crankshaft tail dimensions: one combination for 848, 998 and 1098 engines 22A238 WASHER, thrust, primary gear, front 1 0.127-0.129" (3.22-3.28mm).
and the other for 1071, 1275 and 970 engines. This continued right the way through to 1979 when ‘A 22A239 WASHER, thrust, primary gear, front 1 0.129-0.131" (3.28-3.32mm).
Plus’ gears were introduced, which saw production out through to 2000.
970, 1071 and 1275 Engines
Primary gears are supplied with their bushes fitted, as ready-to-use assemblies. However, if you intend 26 DAM6490 WASHER, thrust, primary gear, front 1 0.112-0.114" (2.84-2.89mm).
to fit replacement bushes in a primary gear, the bushes must be machined after fitment to ensure DAM6486 WASHER, thrust, primary gear, front 1 0.114-0.116" (2.89-2.94mm).
alignment with each other. DAM6487 WASHER, thrust, primary gear, front 1 0.116-0.118" (2.94-2.99mm).
DAM6488 WASHER, thrust, primary gear, front 1 0.118-0.120" (2.99-3.04mm).
By contrast, the idler and 1st motion shaft drive gears saw far fewer changes, being limited to 3 DAM6489 WASHER, thrust, primary gear, front 1 0.120-0.122" (3.04-3.09mm).
synchro gearbox (1959-68), pre-A Plus 4 synchro gearbox (1968-79) and A Plus (1979 on). Of these,
pre-A Plus 4 synchro gears may be used on 3 synchro gearboxes if certain other components are fitted Primary Gear Rear Thrust Washers
at the same time. However, pre-A Plus and A Plus gears cannot be mixed and matched together.
1959-62, Oil-fed Bush 848 Engines
27 2A3597 WASHER, thrust, primary gear, rear 1
Bearings (and their retaining circlips) for the idler and drive gears may be found in the ‘Flywheel
Housing and Clutch Cover’ and ‘Manual Gearbox - External’ sections of this catalogue. Primary, idler and
1961-62, Oil-fed Bush 997 Engines
drive gears for automatic Minis may be found in the ‘Automatic Transmission - Torque Converter and
28 12A382 WASHER, thrust, primary gear, rear 1
Housing’ section.
29 12A383 RING, backing 1

Primary Gears 1962-63, Deva Bush 848 Engines With 1 3/8" dia. Flywheel Machining
Confusion often reigns over the convention for naming primary gear bushes. Which should be called the 30 2A3597 WASHER, thrust, primary gear, rear 1
front bush and which should be the rear? The answer is the bush closer to the front of the engine 31 22A449 RING, backing 1
(i.e. the water pump end) is the front bush and the bush on the clutch end (the ‘top hat’ bush on
post-1962 cars) is the rear bush. Hope that sorts it out. 1962 On, Deva Bush 970, 997, 998, 1098, 1070 and 1275 Engines
With 1 3/8" or 1 1/2" dia. Flywheel Machining
1959-62, Oil-fed Bush 848 Engines 1963 On, Deva Bush 848 Engines With 1 1/2” dia. Flywheel Machining
1 22A79 PRIMARY GEAR, with bushes, 24 teeth 1 32 22A319 WASHER, thrust, primary gear, rear 1
2 22A81 BUSH, primary gear, front 1 33 88G549 RING, backing 1
3 22A82 BUSH, primary gear, rear 1
Idler Gears
1961-62, Oil-fed Bush 997 Engines
34 22A304 IDLER GEAR, 31 teeth, 3/4" shaft dia. 1 1959-68; 3 synchro.
4 12A380 PRIMARY GEAR, with bushes, 24 teeth 1
22G943 IDLER GEAR, 31 teeth, 3/4" shaft dia. 1 1968-79; 4 synchro.
5 12A386 BUSH, primary gear, front 1
TUB101310 IDLER GEAR, 37 teeth, 7/8" shaft dia. 1 1979 on; 4 synchro, A Plus.
6 12A385 BUSH, primary gear, rear 1
The 3 synchro 22A304 idler gear may be replaced by the equivalent gear from the 4 synchro gearbox,
22G943, so long as the original circlip retaining the idler gear bearing in the gearbox case is replaced
1962-63, Deva Bush 848 Engines, 1 3/8" dia. Flywheel Machining
with a 22G1141 circlip.
7 22A520 PRIMARY GEAR, with bushes, 24 teeth 1
8 22A447 BUSH, primary gear, front 1
35 22A1545 WASHER, thrust, 0.130-0.131" (3.30-3.32mm) 2 1959-79; 3 synchro and 4 synchro.
9 22A448 BUSH, primary gear, rear 1
22A1546 WASHER, thrust, 0.132-0.133" (3.35-3.37mm) 2 1959-79; 3 synchro and 4 synchro.
22A1547 WASHER, thrust, 0.134-0.135" (3.40-3.42mm) 2 1959-79; 3 synchro and 4 synchro.
1962-63, Deva Bush 997 Engines, 1 3/8" dia. Flywheel Machining
22A1548 WASHER, thrust, 0.136-0.137" (3.45-3.47mm) 2 1959-79; 3 synchro and 4 synchro.
10 22G106 PRIMARY GEAR, with bushes, 24 teeth 1
22A1549 WASHER, thrust, 0.138-0.139" (3.50-3.53mm) 2 1959-79; 3 synchro and 4 synchro.
11 22G108 BUSH, primary gear, front 1
DAM5914 WASHER, thrust, 0.130-0.131" (3.30-3.32mm) 2 1979 on; 4 synchro, A Plus.
12 22G109 BUSH, primary gear, rear 1
DAM4822 WASHER, thrust, 0.132-0.133" (3.35-3.37mm) 2 1979 on; 4 synchro, A Plus.
DAM4823 WASHER, thrust, 0.134-0.135" (3.40-3.42mm) 2 1979 on; 4 synchro, A Plus.
1963, Deva Bush 997/998 Engines, 1 1/2" dia. Flywheel Machining
DAM4824 WASHER, thrust, 0.136-0.137" (3.45-3.47mm) 2 1979 on; 4 synchro, A Plus.
13 22A551 PRIMARY GEAR, with bushes, 24 teeth 1
DAM4825 WASHER, thrust, 0.138-0.139" (3.50-3.53mm) 2 1979 on; 4 synchro, A Plus.
14 22A553 BUSH, primary gear, front 1
15 22G109 BUSH, primary gear, rear 1
1st Motion Shaft Drive Gears
1963-92, Deva Bush 848/998/1098 Engines, 1 1/2" dia. Flywheel Machining 36 2A3545 DRIVE GEAR, 1st motion shaft, 24 teeth 1 1959-68; 3 synchro.
16 22A1493 PRIMARY GEAR, with bushes, 24 teeth 1 1963-79. 22G849 DRIVE GEAR, 1st motion shaft, 24 teeth 1 1968-79; 4 synchro.
DAM8888 PRIMARY GEAR, with bushes, 29 teeth 1 1979-92; A Plus. DAM2925 DRIVE GEAR, 1st motion shaft, 29 teeth 1 1979 on; A Plus. Not 1275 (France),
17 DAM2821 DUST SHIELD 1 1979-92; A Plus. 1990-96.
18 DAM8887 BUSH, primary gear, front 1 DAM6337 DRIVE GEAR, 1st motion shaft, 28 teeth 1 A Plus. 1275 (France), 1990-96.
19 22G109 BUSH, primary gear, rear 1 The 3 synchro 2A3548 drive gear may be replaced by the 22G849 gear from the 4 synchro gearbox, so
long as distance piece C-STR239 is also used.
1963 On, Deva Bush 970/1071/1275 Engines, 1 1/2" dia. Flywheel Machining
20 22G1053 PRIMARY GEAR, with bushes, 24 teeth 1 1963-79. 37 2A3548 NUT, drive gear to 1st motion shaft 1
DAM8890 PRIMARY GEAR, with bushes, 29 teeth 1 1979 on; A Plus. Not France 1990-96. 38 DAM4000 LOCK TAB 1
DAM9373 PRIMARY GEAR, with bushes, 30 teeth 1 A Plus. France 1990-96.
21 DAM2821 DUST SHIELD 1 1979 on; A Plus.
22 DAM8889 BUSH, primary gear, front 1
23 22G109 BUSH, primary gear, rear 1

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Manual Gearbox - External Components

10 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - External Components
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Rebuilt or Repaired Gearbox Assemblies 40

41
FNZ504
LWZ304
NUT
WASHER, locking
2
2
Somerford Mini Ltd. offers a gearbox rebuilding and repair service through its workshop facility. We can
carry out repairs or rebuilds on late-model gearboxes, but can only realistically offer a repair service for 42 SH604081 SCREW, gearbox case rear to cylinder block5
the earlier designs because of, frankly, poor overall parts availability in the marketplace. Please 43 BH604121 BOLT, gearbox case front to cylinder block 5
contact us to discuss your Mini gearbox requirements - it would be helpful if you could supply us not 44 LWZ304 WASHER, locking 10
only the details of what’s gone wrong with your gearbox, but the age (if known) and type (3 or 4 45 BH604121 BOLT, dowel 1
synchro, A or A Plus, gearchange type and driveshaft type). The more you can provide us with, the 46 12A1150 COLLAR, dowel bolt 1
better we can ascertain how we might possibly help you. 47 PWZ104 WASHER, plain 1
48 FNZ104 NUT 1
It has to be said that at time of writing, spares availability for 1959-68 3 synchromesh gearboxes is not
very good at all and unfortunately because of the high cost involved in reintroducing some components, Gearbox Case Fittings
the situation is unlikely to get much better in the forseeable future. Rest assured, however, that we will 49 GEG804 GASKET SET, gearbox 1 Includes all gaskets, oil seals and sealing
always do whatever we can to help you. The later 4 synchromesh gearboxes fare much better, especially washers; direct and remote gearchange.
of course the rod change variety which were in production between 1973 and 2000. Having said that, GUG708002TS GASKET SET, gearbox 1 Includes all gaskets, oil seals and sealing
there are some surprising gaps in parts availability, even for 1980s rod change gearboxes. washers; rod gearchange to 1996.
GUG708014TS GASKET SET, gearbox 1 Includes all gaskets, oil seals and sealing
The general rule is that the older the gearbox type, the more components are not available new and washers; rod gearchange 1997 on.
the less likely a totally comprehensive rebuild will be possible. 50 18G8085 LOCK TAB KIT, gearbox 1 Includes lock tabs for the differential
cover and oil strainer, for direct,
5 Speed Gearbox Assemblies remote or rod change gearboxes.
5 speed rod-change gearboxes have generated much interest for some years now, with several 51 2A3502 BUSH, gearchange control shaft 2 1959-73 Saloon; 1960-73 Estate;
organisations producing their own designs (Jack Knight Developments, KAD and Mini Spares, for example). 1960-75 Van and Pick Up. Direct and
Please contact us to establish which are currently available. remote gearchange.
52 13H7286 BUSH, ‘Metalastic’, gearchange steady rod 1 1973 on Saloon; 1973-82 Estate;
Differential Cover Attachment 53 AHU1672
1976-84 Van and Pick Up. Rod change.
OIL SEAL, selector shaft, in differential cover1 1973 on Saloon; 1973-82 Estate;
1 2A3505B GASKET, cover to gearbox case, upper 1
2 2A3506B GASKET, cover to gearbox case, lower 1 1959-73 Saloon and Estate; 1960-75 1976-84 Van and Pick Up. Rod change.
Van and Pick Up. Direct or remote 54 DAM7764 BUSH, selector shaft 1 Rod gearchange up to 1985 approx.
gearchange. Replace with SSK001 selector oil seal kit.
3 22G1836B GASKET, cover to gearbox case, lower 1 1973 on Saloon; 1973-82 Estate; 55 DAM8706 BUSH, aluminium, selector shaft, improved 1 Rod gearchange 1985 approx. on.
1976-84 Van and Pick Up. Rod 56 CDU1563 O RING, selector shaft 1 Rod gearchange 1985 approx. on.
gearchange. 57 DAM3022 GAITER, selector shaft 1 1973 on Saloon; 1973-82 Estate;
4 BHYL001 HYLOMAR SEALANT, 100g tube A/R Use with gaskets. 1976-84 Van and Pick Up. Rod change.
5 22A153 DOWEL, cover to gearbox case 2 Selector shaft oil seal failure was always a problem on rod gearchange Minis (as any late-model Mini
6 22G1834 STUD, cover to gearbox case, long 4/2 Qty. reduces for rod gearchange. owner with oil drips on their garage floor will know). The most common remedy effected by owners in
7 FNZ506 NUT 4 the past was to put two oil seals one behind the other on the selector shaft (there’s just enough space
8 CHS522 STUD, cover to gearbox case, short 3 to do so), the outer one of the two acting both as a secondary seal and also as a secondary shield
9 DAM7760 BOLT, flanged, cover to gearbox case, short 3 Alternative to stud from 1985 on. behind the gaiter, protecting the inner seal from under-body muck and grit. Most importantly, the
10 FNZ505 NUT 3 second seal helped to support the selector shaft and hold it in alignment in the gearbox casing.
11 LWZ305 WASHER, locking 3
12 22A74 LOCK TAB, cover to gearbox case, large 2 1959-62 direct gearchange. Factory engineers finally came up with a remedy in 1985, fitting a modified selector shaft bush with a
22A74 LOCK TAB, cover to gearbox case, large 1 Direct or remote gearchange. new O ring to improve the selector shaft alignment. We of course supply all these parts separately, but
13 42H500 LOCK TAB, cover to gearbox case, large 1 Rod gearchange. we’ve also put them together as an easy-to-buy, easy-to-fit kit for the owner to modify a pre-1985 Mini
14 22A251 LOCK TAB, cover to gearbox case, small 1 1962 on. or repair a later model.
15 22A252 LOCK TAB, cover to gearbox case, small 1 1962-71 approx. 58 SSK001 SELECTOR OIL SEAL KIT 1 Includes oil seal, gaiter and improved
The 22A251 and 22A252 small lock tabs replaced one of the 22A74 large lock tabs in 1962. 22A252 bush and O ring.
was quietly dropped in the early 1970s and is no longer considered necessary to fit. 59 88G302 BEARING, idler gear (1.004" ext. dia.) 1 1959-68, 3 synchro gearbox.
13H7848 BEARING, idler gear (1 1/16" ext. dia., 1 1968-79, 4 synchro gearbox.
Flywheel Housing Attachment AHU1707
3/4" int. dia.)
BEARING, idler gear (1 3/8" ext. dia., 1 1979 on, 4 synchro gearbox.
16 GUG705563GM GASKET, housing to cylinder block/gearbox 1
17 22A97 DOWEL, housing to gearbox case 2 7/8" int. dia.)
18 22A152 STUD, housing to gearbox case, long 6 DAM3745 BEARING, idler gear, special, with sleeve 1 For use, see note below.
19 DAM7759 BOLT, flanged, housing to gearbox case, long 6 Alternative to stud from 1985 on. (1 3/8" ext. dia., 3/4" int. dia.)
20 53K547 STUD, housing to gearbox case, short 3 60 CCN216 CIRCLIP, bearing retaining 1 Use with 88G302 bearing and original
21 DAM7756 BOLT, flanged, housing to gearbox case, short 3 Alternative to stud, 1985 on; not Cooper. 3 synchro 22A304 idler gear.
DAM7756 BOLT, flanged, housing to gearbox case, short 1 Alternative to stud, 1985 on; Cooper. 22G1141 CIRCLIP, bearing retaining 1 Use with 88G302 bearing and original
DAM7756 BOLT, flanged, housing to gearbox case, short 2 Alternative to stud, 1985 on; Cooper. 3 synchro 22A304 idler gear or
For nuts, washers and lock tabs for the above studs, plus screws, bolts and lock tabs used to attach the replacement 22G943 idler gear.
flywheel housing to the cylinder block, please see the ‘Flywheel Housing and Clutch Cover’ section. 51K3565 CIRCLIP, bearing retaining 1 Use with 13H7848 bearing.
The DAM3745 bearing with sleeve was intended to allow a post-1979 service gearbox to be fitted to a
Speedometer Pinion Housing Attachment 1973-79 car, retaining the original idler and first motion shaft drive gears in that car. Nowadays it
makes a useful conversion part for those wanting to mix and match their gearbox, idler and drive gears.
22 DAM5219 HOUSING, speedometer pinion 1
23 GUG705569GM GASKET, housing to gearbox case 1
24 22A13 DOWEL, housing to gearbox case 2 61 2A3504 PIVOT PIN, reverse operating lever 1 Direct or remote gearchange.
25 SH505091 SCREW, coarse thread, housing to gearbox 5 62 DAM7335 PLUG, drain, magnetic 1
case DP1 PLUG, drain, magnetic, extended 1 Use with centre oil pick up pipe.
26 LWZ305 WASHER, locking 5 63 AED172 WASHER, sealing, drain plug 1
27 53K1474 STUD, housing to gearbox case 3 64 22A335 STRAINER, oil 1
28 DAM7761 BOLT, flanged, housing to gearbox case 3 Alternative to stud from 1985 on. 65 22A341 O RING, pick up pipe 1
29 53K551 STUD, engine mounting to housing 1 Not 850 models, 1959-68. 66 22A342 BRACKET, strainer 1
53K545 STUD, engine mounting to housing 1 850 models, 1959-68. 67 SH604031 SCREW, strainer to bracket 2
30 FNZ505 NUT 4 68 22A388 LOCK TAB, strainer to bracket 1 Included in 18G8085 lock tab kit.
31 LWZ305 WASHER, locking 4 69 SH604081 SCREW, bracket to gearbox case 2
32 2A3626 END PLATE, housing 1 70 22A1365 LOCK TAB, bracket to gearbox case 1 Included in 18G8085 lock tab kit.
33 GUG705564GM GASKET, end plate to housing 1 71 22G1150 PIPE, oil pick up 1 Not 850 models.
34 SH504061 SCREW, coarse, end plate to housing 2 22A337 PIPE, oil pick up 1 850 models.
35 LWZ304 WASHER, locking 2 72 C-AHT54 PIPE, oil pick up, centre 1 For fast road or competition use; we
advise the use of DP1 extended drain
Cylinder Block Attachment 73 2A3637 FLANGE, pick up pipe, outer 1
plug with this pipe.
36 GUG106SS GASKET SET, gearbox case to cylinder block1
37 AHU1959 SEAL, oil, front main bearing cap 1 ‘Half Moon’ seal. 74 22A542B GASKET, pick up pipe flanges 2
38 22H983 DOWEL, gearbox case to cylinder block 1 75 BH604131 BOLT, pick up pipe flanges to gearbox case 2
39 FHS2410 STUD, gearbox case to thick flanged block 2 Not Cooper or Cooper S models, 1961-67. 76 2K4874 LOCK TAB, flanges to gearbox case 1 Included in 18G8085 lock tab kit.
FHS2409 STUD, gearbox case to thin flanged block 2 Cooper and Cooper S models, 1961-67. 77 2A3606 O RING, gearbox case to cylinder block 1

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Manual Gearbox - 3 Synchro Internal Components

12 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - 3 Synchro Internal Components
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

The 3 Synchro Gearbox thing to remember here is don’t embark on a 3 synchro gearbox rebuild until (a) you’re absolutely sure
you have the parts you need; and (b) you’ve weighed up seriously the benefits of sourcing another, better
1959-68
condition, gearbox instead. You have been warned...
Fitted to all Minis between 1959 and 1968, the 3 synchro gearbox is so called because synchromesh is
only available on 2nd, 3rd and 4th gears, 1st gear being of the ‘crash’ engagement type. Probably the
Close Ratio and Straight Cut Gears
most common fault on this gearbox is jumping out of first gear, followed closely by laygear bearing and
Close ratio straight cut gear sets are available to build into gearboxes with B Type Gears components, as
layshaft failure. A proper first speed gear was inserted in the gearbox in 1968, at last receiving the
a special order. Please contact us for details. Similarly, please contact us if you have factory-optional
great benefit of synchromesh engagement; this gearbox is known as the 4 synchro and its internal
(Special Tuning) helical close ratio, straight cut close ratio or straight cut standard ratio gears in your
components are covered in the next section of the catalogue.
gearbox and you require replacement parts.
If you’ve not been inside a 3 synchro Mini gearbox before or you can’t remember when you last did,
Reverse Idler Gear
please read these notes carefully - they could save you a lot of heartache. The gearbox internal
1 22A377 REVERSE IDLER, with bush, 18 teeth 1 1959-64; 848 models, Cone Synchro
components were revised several times, with the changes being introduced at broadly the same times
and A Type gears.
across all of the A series engined cars in the BMC range. Essentially, these revisions boil down to three
1961-62; 997 Cooper, Cone Synchro.
types of gearbox (with a handful of components being awkward exceptions to the rule, of course... we’ll
1962-63; 997 Cooper, A Type gears.
explain those as best we can as we go along).
1963; 997 Cooper, A Type gears.
22G202 REVERSE IDLER, with bush, 18 teeth 1 1963-64; 997/998 Cooper, 1071
The first 3 synchro gearbox fitted to the Mini is known as the ‘cone synchromesh’ gearbox, because of
Cooper S, A Type gears with B Type
its use of cones to aid gearchanging rather than the more efficient baulk rings, which arrived in 1962.
1st/2nd synchroniser and reverse.
The next change occurred in 1963 or 1964 (depending on model) when the angles of the gear teeth
1964-68; 848 and 998 (not Cooper)
were changed to quieten the baulk ring gearbox. The modified gears were known as B Type gears, the
models, B Type gears.
1962-63 gears retrospectively becoming known as A Type gears. So there you have it: 1959-62 Cone
1964-68; 998 Cooper, 970/1071/1275
Synchromesh gearbox, 1962-63/64 A Type Gears gearbox and 1963/64-68 B Type Gears gearbox (plus, in
Cooper S, B Type gears.
1963-64, an A Type gearbox with B Type 1st/2nd synchroniser and reverse idler...!).
2 2A3475 BUSH, reverse idler 1
3 DAM8038 SHAFT, reverse idler 1
Gearbox Identification
Identifying your 3 synchro gearbox can be a very complicated process, bourne out by the unfortunately
Laygear
necessarily complex guidelines below.
4 22A381 LAYGEAR, 13/19/24/28 teeth 1 1959-64; 848 models, Cone Synchro
and A Type gears.
Between the three 3 synchro gearbox types, many, many components are not interchangeable. This
22A350 LAYGEAR, 13/19/23/26 teeth 1 1961-62; 997 Cooper, Cone Synchro.
makes it especially important to identify your gearbox before ordering parts, which can be difficult,
22G76 LAYGEAR, 13/19/23/26 teeth 1 1962-63; 997 Cooper, A Type gears.
particularly when trying to work out whether you have A or B Type gears. Originally, gearbox cases
22G197 LAYGEAR, 13/19/23/26 teeth 1 1963; 997 Cooper, A Type gears.
were stamped with a part number denoting the gear types within and the model application; however
22G204 LAYGEAR, 13/19/23/26 teeth 1 1963-64; 997/998 Cooper, 1071
this has become quite irrelevant over the years as gearboxes have been rebuilt, very often with different
Cooper S, A Type gears with B Type
components to overcome the lack of original parts availability.
1st/2nd synchroniser and reverse.
22G231 LAYGEAR, 13/19/24/28 teeth 1 1964-68; 848 and 998 (not Cooper)
The only surefire way to identify the gearbox nowadays is to inspect the internals with a check list to
models, B Type gears.
hand, paying particular attention to:
22G1100 LAYGEAR, 13/19/23/26 teeth 1 1964-68; 998 Cooper, 970/1071/1275
(i) the presence of synchro cones or baulk rings (denoting a Cone Synchro box in the first instance and
Cooper S, B Type gears.
an A Type or B Type box in the second);
5 22A1371 LAYSHAFT 1
(ii) If baulk rings are present, establish whether the second and third gears run on bushes (the bush
6 2A3581 PLATE, locating reverse idler shaft/layshaft 1
interlocking ring being visible between the two gears on the mainshaft gear cluster) or bearings. A Type
7 88G396 BEARING, needle roller, laygear 2
gearboxes except in the 1963 Cooper 997 run on bushes; the second and third gears in A Type
8 22G277 DISTANCE PIECE, bearing 1
gearboxes in the 1963 Cooper 997 run on bearings, as is the case with the similarly short-lived Cooper
9 22G278 CIRCLIP, bearing retaining 2
and Cooper S gearbox with hybrid A/B Type gears and all gearboxes with B Type gears.
10 88G325 WASHER, thrust, large 1 0.123-0.124" (3.12-3.14mm).
(iii) Count the number of teeth on the laygear cluster. A combination of 13/19/24/28 teeth is the
88G326 WASHER, thrust, large 1 0.125-0.126" (3.17-3.20mm).
regular set-up for non Cooper models and 13/19/23/26 for Cooper. Other combinations were available
88G327 WASHER, thrust, large 1 0.127-0.128" (3.22-3.25mm).
only as Special Tuning options.
88G328 WASHER, thrust, large 1 0.130-0.131" (3.30-3.32mm).
(iv) Are the laygear bearing circlips on the outside or inside of the bearings? Cone Synchro and A Type
11 88G324 WASHER, thrust, small 1
gears except 1963 Cooper 997 use outside laygear bearing circlips, whereas A Type gearbox in the 1963
Cooper 997, the hybrid A/B Type gearbox and B Type gearboxes use inside circlips.
1st Motion Shaft
12 22A88 SHAFT, 1st motion, 19 teeth, with cone 1 1959-62; 848 models, Cone Synchro.
The laygear should tell you which combination of gears you have... we say ‘should’ because the laygear
22A588 SHAFT, 1st motion, 19 teeth 1 1962-64; 848 models, A Type gears.
part number was traditionally stamped on the component between the largest and second largest gears,
22A257 SHAFT, 1st motion, 20 teeth, with cone 1 1961-62; 997 Cooper, Cone Synchro.
but some reproduction gears (mostly in the case of 22G1100) don’t have this stamping. Identifying
22A416 SHAFT, 1st motion, 20 teeth 1 1962-63; 997 Cooper, A Type gears.
your laygear allows you to work out what other gears have been used in the gearbox, since they were
22A592 SHAFT, 1st motion, 20 teeth 1 1963; 997 Cooper, A Type gears.
designed to go together as matched gear sets and are usually not interchangeable. For this reason, all
1963-64; 997/998 Cooper, 1071
the other major components in this section use the application remarks shown alongside the laygears -
Cooper S, A Type gears with B Type
even if it’s a bit long-winded sometimes, it positively matches the sets together.
1st/2nd synchroniser and reverse.
22A979 SHAFT, 1st motion, 19 teeth 1 1964-68; 848 and 998 (not Cooper)
Be careful with gearboxes in 848 models and 997 Coopers using A Type gears, though - some have been
models, B Type gears.
converted from cone synchro to baulk ring A Type gears, retaining the original laygear; some other
22A982 SHAFT, 1st motion, 20 teeth 1 1964-68; 998 Cooper, 970/1071/1275
components used in cone to baulk ring converted gearboxes are unique and most are not listed here
Cooper S, B Type gears.
(this catalogue section is complicated enough!). The 22G1100 laygear, incidentally, was for a short
13 2A3693 CONE, synchronising 1 For 22A88 and 22A257 1st motion shafts.
period at the start of its life known as and stamped as 22G232. Lastly, if you find 22G83 or 22G714
Note that synchro cones have to be shrunk onto their respective gears and then finally machined - not a
on your laygear, you have an Austin/Morris 1100 or 1300 gearbox, not a Mini one.
task for most home-based Mini restorers.
Parts Availability
14 22G2033 RING, baulk 1 For all other 1st motion shafts.
Unfortunately, parts availability ranges from almost hopeless (Cone Synchromesh and A Type gears)
15 22G314 BEARING, 1st to 3rd motion shaft 1 For 22A88, 22A588, 22A257 and
through to pretty awful (B Type gears) and this situation is unlikely to improve greatly in the future.
22A416 1st motion shafts.
The B Type gears do, however, benefit marginally from the fact that the MG Midget continued to use
CHM172 BEARING, needle roller, 1st to 3rd 1 For 22A592, 22A979 and 22A982
versions of them until 1974, which slightly increases parts demand and availability. Many parts listed in
motion shaft 1st motion shafts.
this section are therefore shown only as a matter of reference.
16 2A3709 BEARING, 1st motion shaft 1 In gearbox case.
17 2A3710 CIRCLIP, bearing retaining 1 0.094-0.096" (2.39-2.44mm)
We will always do our utmost to help you seek out parts for your gearbox, but by rule of thumb the
2A3711 CIRCLIP, bearing retaining 1 0.097-0.099" (2.46-2.51mm)

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Manual Gearbox - 3 Synchro Internal Components

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 Manual Gearbox - 3 Synchro Internal Components
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

1st Motion Shaft (Continued) 34 2A3298 BUSH, 2nd speed gear 1 For 22A90 or 22A582 2nd speed gears.
For the 1st motion shaft bearing supporting the nose of the shaft in the flywheel housing, please see 35 22G374 RING, interlocking, 2nd/3rd gear bushes 1 For 22A90 or 22A582 2nd speed gears.
the ‘Flywheel Housing and Clutch Cover’ section. 36 22G186 COLLAR, locking, 2nd speed gear 1 For 22G194 or 22A980 2nd speed gears.
37 22G149 BEARING, needle roller, 2nd speed gear 26 For 22G194 or 22A980 2nd speed gears.
3rd Motion Shaft 38 22G157 WASHER, 2nd speed gear locking collar 2 For 22G194 or 22A980 2nd speed gears.
18 2A3719 SHAFT, 3rd motion 1 1959-61; 848 models, Cone Synchro. 39 22A495 PEG, 2nd speed gear locking collar 1 For 22G194 or 22A980 2nd speed gears.
1961; 997 Cooper, Cone Synchro. 40 22G154 SPRING, 2nd speed gear locking collar 1 For 22G194 or 22A980 2nd speed gears.
22A425 SHAFT, 3rd motion 1 1961-62; 848 models, Cone Synchro.
1961-62; 997 Cooper, Cone Synchro. 3rd Gear
22A421 SHAFT, 3rd motion 1 1959-62; Cone Synchro to baulk ring 41 22A89 GEAR, 3rd speed, 23 teeth, with cone 1 1959-62; 848 models, Cone Synchro.
synchro conversion item. 22A583 GEAR, 3rd speed, 23 teeth 1 1962-64; 848 models, A Type gears.
22G70 SHAFT, 3rd motion 1 1962-64; 848 models, A Type gears. 22A261 GEAR, 3rd speed, 24 teeth, with cone 1 1961-62; 997 Cooper, Cone Synchro.
1962-63; 997 Cooper, A Type gears. 22A415 GEAR, 3rd speed, 24 teeth 1 1962-63; 997 Cooper, A Type gears.
1963; 997 Cooper, A Type gears. 22G195 GEAR, 3rd speed, 24 teeth 1 1963; 997 Cooper, A Type gears.
1963-64; 997/998 Cooper, 1071 1963-64; 997/998 Cooper, 1071
Cooper S, A Type gears with B Type Cooper S, A Type gears with B Type
1st/2nd synchroniser and reverse. 1st/2nd synchroniser and reverse.
22G392 SHAFT, 3rd motion 1 1964-68; 848 and 998 (not Cooper) 22A981 GEAR, 3rd speed, 23 teeth 1 1964-68; 848 and 998 (not Cooper)
models, B Type gears. models, B Type gears.
1964-68; 998 Cooper, 970/1071/1275 22A983 GEAR, 3rd speed, 24 teeth 1 1964-68; 998 Cooper, 970/1071/1275
Cooper S, B Type gears. Cooper S, B Type gears.
19 22A422 WASHER, spacing 1 1959-62; Cone Synchro to baulk ring 42 2A3693 CONE, synchronising 1 For 22A89 or 22A261 2nd speed gears.
synchro conversion item. 43 22G2033 RING, baulk 1 For all other 2nd speed gears.
20 2A3712 BEARING, 3rd motion shaft 1 For 2A3719, 22A425 or 22A421 shafts. 44 2A3290 BUSH, 3rd speed gear 1 For 22A89, 22A583, 22A261 or
22A575 BEARING, 3rd motion shaft 1 1959-62; Cone Synchro to baulk ring 22A415 3rd speed gears.
type gearbox case conversion. For 45 22A550 WASHER, thrust, 0.212-0.213" 1 For 22A89, 22A583, 22A261 or
2A3719 or 22A425 shafts. (5.38-5.41mm) 22A415 3rd speed gears.
AAU1365 BEARING, 3rd motion shaft 1 For 22G70 or 22G392 3rd motion shafts. 22A536 WASHER, thrust, 0.214-0.215" 1 For 22A89, 22A583, 22A261 or
21 2A3713 RING, spring, bearing retaining 1 Fit to 2A3712 bearing. (5.43-5.46mm) 22A415 3rd speed gears.
ADU4992 RING, spring, bearing retaining 1 Fit to AAU1365 bearing. 22A537 WASHER, thrust, 0.216-0.217" 1 For 22A89, 22A583, 22A261 or
22 2A3716 RETAINER, 3rd motion shaft bearing 1 For 2A3712 3rd motion shaft bearing. (5.48-5.51mm) 22A415 3rd speed gears.
22A522 RETAINER, 3rd motion shaft bearing 1 For AAU1365 3rd motion shaft bearing. 22A538 WASHER, thrust, 0.218-0.219" 1 For 22A89, 22A583, 22A261 or
23 SH505081 SCREW, retainer to gearbox case 4 (5.53-5.56mm) 22A415 3rd speed gears.
24 DAM2377 LOCK TAB, screw 2 46 22A495 PEG, thrust washer 1 For 22A89, 22A583, 22A261 or
25 2A3714 SHIM, retainer A/R 0.003" (0.076mm) 22A415 3rd speed gears.
2A3715 SHIM, retainer A/R 0.010" (0.254mm) 47 22A528 SPRING, thrust washer 1 For 22A89, 22A583, 22A261 or
22A415 3rd speed gears.
1st/2nd Synchroniser 48 22G149 BEARING, needle roller, 3rd speed gear 26 For 22G195, 22A981 or 22A983
26 22A433 GEAR ASS’Y, 1st/2nd synchroniser 1 1959-62; 848 models, Cone Synchro. 3rd speed gears.
1961-62; 997 Cooper, Cone Synchro. 49 22G196 COLLAR, locking, 3rd speed gear 1 For 22G195, 22A981 or 22A983
22G440 GEAR ASS’Y, 1st/2nd synchroniser 1 1962-64; 848 models, A Type gears. 3rd speed gears.
1962-63; 997 Cooper, A Type gears. 50 22A495 PEG, 3rd speed gear locking collar 1 For 22G195, 22A981 or 22A983
1963; 997 Cooper, A Type gears. 3rd speed gears.
22A1021 GEAR ASS’Y, 1st/2nd synchroniser 1 1963-64; 997/998 Cooper, 1071 51 22G154 SPRING, 3rd speed gear locking collar 1 For 22G195, 22A981 or 22A983
Cooper S, A Type gears with B Type 3rd speed gears.
1st/2nd synchroniser and reverse.
1964-68; 848 and 998 (not Cooper) 3rd/4th Synchroniser
models, B Type gears. 52 22A26 GEAR ASS’Y, 3rd/4th synchroniser 1 1959-62; 848 models, Cone Synchro.
1964-68; 998 Cooper, 970/1071/1275 1961-62; 997 Cooper, Cone Synchro.
Cooper S, B Type gears. 22G97 GEAR ASS’Y, 3rd/4th synchroniser 1 1962-64; 848 models, A Type gears.
The 1st speed outer ring for the 22A1021 gear assembly is sometimes available separately as the repair 1962-63; 997 Cooper, A Type gears.
part 22A1021A. However its compatibility with an old 2nd speed synchro hub cannot be completely 22G410 GEAR ASS’Y, 3rd/4th synchroniser 1 1963; 997 Cooper, A Type gears.
guaranteed as the outer ring and hub were designed to be supplied as a matched pair. 1963-64; 997/998 Cooper, 1071
Cooper S, A Type gears with B Type
27 BLS107 BALL, synchroniser 6/3 Qty. 6 used on very early Cone Synchro. 1st/2nd synchroniser and reverse.
28 22A367 SPRING, synchroniser 6/3 Qty. 6 used on very early Cone Synchro. 1964-68; 848 and 998 (not Cooper)
29 22G89 PLUNGER, 2nd speed synchroniser 1 models, B Type gears.
1964-68; 998 Cooper, 970/1071/1275
2nd Gear Cooper S, B Type gears.
30 22A90 GEAR, 2nd speed, with synchro cone, 1 1959-62; 848 models, Cone Synchro. 53 BLS107 BALL, synchroniser 6/3 Qty. 6 used on Cone Synchro.
28 teeth 1961-62; 997 Cooper, Cone Synchro. 54 22A367 SPRING, synchroniser 6/3 Qty. 6 used on Cone Synchro.
22A582 GEAR, 2nd speed, 28 teeth 1 1962-64; 848 models, A Type gears.
1962-63; 997 Cooper, A Type gears. Final Drive Pinion
22G194 GEAR, 2nd speed, 28 teeth 1 1963; 997 Cooper, A Type gears. 55 22G99 PINION, final drive, 15 teeth, 4.333:1 ratio 1 With 65 tooth 22G443 final drive gear.
1963-64; 997/998 Cooper, 1071 22G99 PINION, final drive, 15 teeth, 4.267:1 ratio 1 With 64 tooth 22G370 final drive gear.
Cooper S, A Type gears with B Type 22G99 PINION, final drive, 15 teeth, 4.133:1 ratio 1 With 62 tooth 22G101 final drive gear.
1st/2nd synchroniser and reverse. 22G338 PINION, final drive, 16 teeth, 3.938:1 ratio 1 With 63 tooth 22G340 final drive gear.
22A980 GEAR, 2nd speed, 28 teeth 1 1964-68; 848 and 998 (not Cooper) 22A399 PINION, final drive, 17 teeth, 3.765:1 ratio 1 With 64 tooth 22A401 final drive gear.
models, B Type gears. 22A399 PINION, final drive, 17 teeth, 3.647:1 ratio 1 With 62 tooth 22G940 final drive gear.
1964-68; 998 Cooper, 970/1071/1275 22A413 PINION, final drive, 18 teeth, 3.444:1 ratio 1 With 62 tooth 22A411 final drive gear.
Cooper S, B Type gears. 56 2A3575 NUT, pinion retaining 1 For 2A3719 3rd motion shaft.
31 2A3693 CONE, synchronising 1 For 22A90 2nd speed gear. 57 2A3576 LOCK TAB, pinion nut 1 For 2A3719 3rd motion shaft.
32 22G2033 RING, baulk 1 For 22A582, 22G194 or 22A980 gears. 58 DAM7485 NUT, pinion retaining 1 For all other 3rd motion shafts.
33 2A3042 WASHER, thrust, 2nd speed gear 1 1959-64; all Cone Synchro and A Type 59 DAM6140 LOCK TAB, pinion nut 1 For all other 3rd motion shafts.
2nd speed gears.

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Manual Gearbox - 4 Synchro Internal Components

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 Manual Gearbox - 4 Synchro Internal Components
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

The 4 Synchro Gearbox DAM3092 SHAFT, 1st motion, 17 teeth 1 1979-82; not 1275 models.
1968 On DAM3167 SHAFT, 1st motion, 18 teeth 1 1979-80; 1275 models.
Fortunately 4 synchro gearboxes are much easier to identify and classify than their 3 synchro DAM4930 SHAFT, 1st motion, 17 teeth, A Plus type 1 1982 on; not 1990-96, 1275 (France).
predecessors (parts availability is considerably better, too, but not brilliant in some areas). The two DAM6242 SHAFT, 1st motion, 16 teeth, A Plus type 1 1990-96, 1275 (France).
main changes are the modification of gear shafts and several of the bearings in 1979, and A Plus gears. 16 22G2033 RING, baulk 1
17 CHM172 BEARING, 1st/3rd motion shafts, 9/16” i.d.1 For 22G1093/22G1371 1st motion shafts.
A Plus gears were progressively introduced, the bulk of models changing over around 1982. They have 13H9513 BEARING, 1st/3rd motion shafts, 11/16” i.d.1 For all other 1st motion shafts.
a sharper tooth angle and different pitch making them quieter than the earlier gears, with which they 18 ADU7619 BEARING, 1st motion shaft 1 In gearbox case.
are not interchangeable. A Plus gears may be identified by the presence of a circumferential groove in 19 22G850 CIRCLIP, bearing retaining 1 0.094-0.096" (2.39-2.44mm)
the centre of the teeth, plus flush machining on both sides of the final drive pinion. 22G851 CIRCLIP, bearing retaining 1 0.097-0.099" (2.46-2.51mm)
For the 1st motion shaft bearing supporting the nose of the shaft in the flywheel housing, please see the
The following summaries help with identification and give you points to watch for when ordering parts: ‘Flywheel Housing and Clutch Cover’ section.

1968-73 Saloon and Estate, 1968-75 Van and Pick Up 3rd Motion Shaft
Pre-A Plus gears. Direct/remote gearchange type reverse gear and mainshaft bearing retainer (four 20 22G833 SHAFT, 3rd motion, 9/16" nose dia. 1 1968-79.
screw fitting). 9/16" dia. nose on 3rd motion shaft, two step layshaft, laygear takes two large bearings DAM7484 SHAFT, 3rd motion, 11/16" nose dia. 1 1979 on.
and one small bearing. Different ratios for 1275 models. 21 AAU1365 BEARING, 3rd motion shaft 1
22 ADU4992 RING, spring, bearing retaining 1
1973-79 Saloon and Estate, 1975-79 Van and Pick Up 23 22A522 RETAINER, 3rd motion shaft bearing, 1 1968-73, Saloons and Estates;
Pre-A Plus gears. Rod gearchange type reverse gear and mainshaft bearing retainer (4 screw fitting). 4 screw fixing, direct/remote change type 1968-75, Vans and Pick Ups.
9/16" dia. nose on 3rd motion shaft, two step layshaft, laygear takes two large bearings and one small DAM1756 RETAINER, 3rd motion shaft bearing, 1 1973-84, Saloons and Estates;
bearing. Different ratios for 1275 models. 4 screw fixing, rod change type 1976-84, Vans and Pick Ups.
24 DAM5996 RETAINER, 3rd motion shaft bearing, 1 1984 on.
1979-82 3 screw fixing, rod change type
Pre-A Plus gears (except for final drive pinion on 3.444:1 ratio models, which became A Plus in 1979). 25 SH505071 SCREW, retainer to gearbox case 4/3 Qty. 4 for 22A522/DAM1756 retainers.
Rod gearchange type reverse gear and mainshaft bearing retainer (4 screw fitting). 11/16" dia. nose on 26 DAM2377 LOCK TAB, screw 2/1 Qty. 2 for 22A522/DAM1756 retainers.
3rd motion shaft, three step layshaft, laygear takes one large and one small bearing. Idler and 1st 27 DAM6047 LOCK TAB, screw 1 For DAM5996 retainer.
motion shaft drive gear ratios revised, idler gear bearings in gearbox case revised (diameter change). 28 2A3714 SHIM, retainer A/R 0.003" (0.076mm)
Different ratios for 1275 models. 2A3715 SHIM, retainer A/R 0.010" (0.254mm)

1982 on 1st Gear

A Plus gears. Rod gearchange type reverse gear and mainshaft bearing retainer (4 screw fitting 29 22G1096 GEAR, 1st speed, 31 teeth 1
reducing to 3 screw fitting in 1984). 11/16" dia. nose on 3rd motion shaft, three step layshaft, laygear 30 22G2033 RING, baulk 1
takes one large and one small bearing. Different ratios for French 1275 models in the 1990s. 31 AAU1815 BEARING, needle roller, 1st speed gear 1
32 22G837 JOURNAL, 1st speed gear 1
Close ratio and straight cut close ratio gear sets are available for 4 synchro pre-A Plus and A Plus
gearboxes, as special orders; please contact us for details. Similarly, contact us if you already have 1st/2nd Synchroniser
Special Tuning helical close ratio or straight cut close ratio gears and you require replacement parts. 33 DAM7455 GEAR ASS’Y, 1st/2nd synchroniser 1
34 BLS107 BALL, synchroniser 3
Reverse Idler Gear 35 22G2262 SPRING, synchroniser 3
1 22G1034 REVERSE IDLER, 17/18 teeth, 1 1968-73, Saloons and Estates;
direct/remote gearchange type 1968-75, Vans and Pick Ups. 2nd Gear
22G1832 REVERSE IDLER, 17/18 teeth, 1 1973-79, Saloons and Estates; 36 22G1094 GEAR, 2nd speed, 26 teeth 1 1968-82.
rod gearchange type 1976-79, Vans and Pick Ups. DAM4932 GEAR, 2nd speed, 26 teeth, A Plus type 1 1982 on; not 1990-96, 1275 (France).
TUB10020 REVERSE IDLER, 17/18 teeth, 1 1979 on. DAM6240 GEAR, 2nd speed, 25 teeth, A Plus type 1 1990-96, 1275 (France).
rod gearchange type 37 22G2033 RING, baulk 1
2 TUJ10001 BUSH, reverse idler 1 38 AAU1816 BEARING, needle roller, 2nd speed gear 1
3 DAM8038 SHAFT, reverse idler 1 39 22G839 WASHER, thrust, 2nd speed gear 1
40 22G843 PEG, 2nd speed gear 2
Laygear 41 22G154 SPRING, 2nd speed gear 1
4 22G927 LAYGEAR, 15/20/25/29 teeth 1 1968-79; 2 step layshaft, not 1275.
22G1040 LAYGEAR, 15/20/25/29 teeth 1 1968-79; 2 step layshaft, 1275. 3rd Gear
5 DAM3169 LAYGEAR, 15/20/25/29 teeth 1 1979-82; 3 step layshaft, not 1275. 42 22G1095 GEAR, 3rd speed, 21 teeth 1 1968-82.
DAM3168 LAYGEAR, 15/20/25/29 teeth 1 1979-80; 3 step layshaft, 1275. DAM4933 GEAR, 3rd speed, 21 teeth, A Plus type 1 1982 on; not 1990-96, 1275 (France).
DAM4931 LAYGEAR, 15/21/26/30 teeth, A Plus type 1 1982 on; 3 step layshaft, DAM6241 GEAR, 3rd speed, 20 teeth, A Plus type 1 1990-96, 1275 (France).
not 1990-96, 1275 France. 43 22G2033 RING, baulk 1
DAM6238 LAYGEAR, 15/21/27/31 teeth, A Plus type 1 1990-96, 3 step layshaft, 1275 France. 44 AAU1816 BEARING, needle roller, 3rd speed gear 1
6 22G931 LAYSHAFT, two step type 1 Fit to 22G927 and 22G1040 laygears. 45 22G947 WASHER, thrust, 3rd speed gear 1
7 DAM3187 LAYSHAFT, three step type 1 Fit to all other laygears. 46 22G843 PEG, 3rd speed gear 1
8 2A3581 PLATE, locating reverse idler shaft/layshaft1 47 22G154 SPRING, 3rd speed gear 1
9 CHM141 BEARING, needle roller, laygear, large 2/1 Qty. 2 in 22G927/22G1040 gears only.
10 88G396 BEARING, needle roller, laygear, small 1 Fit to 22G927 and 22G1040 gears only. 3rd/4th Synchroniser
11 13H9513 BEARING, needle roller, laygear, small 1 Fit to all other laygears. 48 DAM7456 GEAR ASS’Y, 3rd/4th synchroniser 1
12 22G856 WASHER, thrust, small, 0.123-0.124" 1 Fit to 22G927 and 22G1040 laygears. 49 BLS107 BALL, synchroniser 3
(3.12-3.14mm) 50 22G2262 SPRING, synchroniser 3
22G857 WASHER, thrust, small, 0.125-0.126" 1 Fit to 22G927 and 22G1040 laygears.
(3.17-3.20mm) Final Drive Pinion
22G858 WASHER, thrust, small, 0.127-0.128" 1 Fit to 22G927 and 22G1040 laygears. 51 22G99 PINION, 15 teeth, 4.333:1 ratio 1 With 65 tooth 22G443 final drive gear.
(3.22-3.25mm) 22G99 PINION, 15 teeth, 4.267:1 ratio 1 With 64 tooth 22G370 final drive gear.
22G859 WASHER, thrust, small, 0.130-0.131" 1 Fit to 22G927 and 22G1040 laygears. 22G99 PINION, 15 teeth, 4.133:1 ratio 1 With 62 tooth 22G101 final drive gear.
(3.30-3.32mm) 22G338 PINION, 16 teeth, 3.938:1 ratio 1 With 63 tooth 22G340 final drive gear.
13 DAM3180 WASHER, thrust, small, 0.121-0.123" 1 Fit to DAM3169, DAM3168, DAM4931 22A399 PINION, 17 teeth, 3.765:1 ratio 1 With 64 tooth 22A401 final drive gear.
(3.07-3.12mm) and DAM6238 laygears. 22A399 PINION, 17 teeth, 3.647:1 ratio 1 With 62 tooth 22G940 final drive gear.
DAM3181 WASHER, thrust, small, 0.124-0.126" 1 Fit to DAM3169, DAM3168, DAM4931 22A413 PINION, 18 teeth, 3.444:1 ratio 1 With 62 tooth 22A411 final drive gear.
(3.15-3.20mm) and DAM6238 laygears. DAM3647 PINION, 15 teeth, A Plus, 4.333:1 ratio 1 With 65 tooth DAM3645 final drive gear.
DAM3182 WASHER, thrust, small, 0.127-0.129" 1 Fit to DAM3169, DAM3168, DAM4931 DAM3218 PINION, 16 teeth, A Plus, 3.938:1 ratio 1 With 63 tooth DAM3216 final drive gear.
(3.22-3.27mm) and DAM6238 laygears. DAM4131 PINION, 17 teeth, A Plus, 3.765:1 ratio 1 With 64 tooth DAM4779 final drive gear.
DAM3183 WASHER, thrust, small, 0.130-0.132" 1 Fit to DAM3169, DAM3168, DAM4931 DAM4131 PINION, 17 teeth, A Plus, 3.647:1 ratio 1 With 62 tooth DAM4162 final drive gear.
(3.30-3.35mm) and DAM6238 laygears. DAM2679 PINION, 18 teeth, A Plus, 3.444:1 ratio 1 With 62 tooth DAM2677 final drive gear.
14 22G860 WASHER, thrust, large 1 DAM2808 PINION, 19 teeth, A Plus, 3.211:1 ratio 1 With 61 tooth DAM2806 final drive gear.
DAM2808 PINION, 19 teeth, A Plus, 3.105:1 ratio 1 With 59 tooth DAM6327 final drive gear.
1st Motion Shaft DAM5927 PINION, 20 teeth, A Plus, 2.950:1 ratio 1 With 59 tooth DAM5925 final drive gear.
15 22G1093 SHAFT, 1st motion, 17 teeth 1 1968-79; not 1275 models. TCC10001 PINION, 21 teeth, A Plus, 2.762:1 ratio 1 With 58 tooth TCB10004 final drive gear.
22G1371 SHAFT, 1st motion, 18 teeth 1 1968-79; 1275 models. 52 DAM7485 NUT, pinion retaining 1
53 DAM6140 LOCK TAB, pinion nut 1

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Manual Gearbox - Selectors and Speedometer Drives

18 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - Selectors and Speedometer Drives
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Direct and Remote Gearchange Selectors 53 22G2595 ROLL PIN, 3rd and 4th speed fork to 1
shaft
1959-73, Saloon and Estate; 1960-75, Van and Pick Up
54 22G1858 SHAFT, selector 1
1 22A611 FORK, 1st and 2nd speed 1 3 synchromesh, 1959-68.
55 AHU1672 OIL SEAL, selector shaft, in differential 1
22G889 FORK, 1st and 2nd speed 1 4 synchromesh, 1968 on.
cover
2 22A167 ROD, 1st and 2nd speed fork 1 3 synchromesh, 1959-68.
56 DAM7764 BUSH, selector shaft 1 1973-85 approx.; replace with SSK001
22G821 ROD, 1st and 2nd speed fork 1 4 synchromesh, 1968 on.
selector oil seal kit.
3 22A610 FORK, 3rd and 4th speed 1
57 DAM8706 BUSH, aluminium, selector shaft 1 1985 approx. on (improved design).
4 22A168 ROD, 3rd and 4th speed fork 1 3 synchromesh, 1959-68.
58 CDU1563 O RING, selector shaft 1 1985 approx. on (improved design).
22G822 ROD, 3rd and 4th speed fork 1 4 synchromesh, 1968 on.
59 DAM3022 GAITER, selector shaft 1
5 22G827 FORK, reverse 1
Selector shaft oil seal failure was always a problem on rod gearchange Minis (as any late-model Mini
6 22A169 ROD, reverse fork 1
owner with oil drips on their garage floor will know). The most common remedy effected by owners in
7 88G213 SELECTOR, reverse fork rod 1
the past was to put two oil seals one behind the other on the selector shaft (there’s just enough space
8 22G826 LEVER, reverse fork 1
to do so), the outer one of the two acting both as a secondary seal and also as a secondary shield
9 2A3504 PIVOT PIN, reverse fork lever 1
behind the gaiter, protecting the inner seal from under-body muck and grit. Most importantly, the
10 CCN108 CIRCLIP, lever to pivot pin 1
second seal helped to support the selector shaft and hold it in alignment in the gearbox casing.
11 2A3492 SCREW, fork and selector locating 3
12 LWZ404 WASHER, shakeproof 3
Factory engineers finally came up with a remedy in 1985, fitting a modified selector shaft bush with a
13 FNZ604 NUT, locking 3
new O ring to improve the selector shaft alignment. We of course supply all these parts separately, but
When reassembling the gearbox, ensure that the fork locating screws are securely locked in place. It’s
we’ve also put them together as an easy-to-buy, easy-to-fit kit for the owner to modify a pre-1985 Mini
not unknown for one of them to vibrate loose otherwise, allowing a fork to slide on its rod and
or repair a later model:
resulting in a complete loss of ability to select the gears operated by that fork; removal of the engine
60 SSK001 SELECTOR OIL SEAL KIT 1 Includes oil seal, gaiter and improved
and gearbox from the car to tighten up one screw is a painful lesson indeed.
bush and O ring.
We know of one occasion where two valiant souls entered in the Italian Job event drove their Mini right
61 22G1844 SPOOL, interlock 1
the way through the Alps and most of the way across northern Italy in first and second gears only, the
62 BLS110 BALL, detent 1
third/fourth selector fork screw having worked loose! The engine and gearbox duly removed in an
63 22G2083 SPRING, detent ball 1
Italian hotel car park, the screw was retightened allowing the Mini to return across Europe to Britain
64 22G1870 SLEEVE, detent 1
under its own steam and with a full complement of forward gears (which no doubt allowed the drivers’
65 22G1417 O RING, sleeve 1
hearing to recover somewhat).
66 22G1845 PIN, pivot, bellcrank 1
67 31B447 O RING, pivot pin 1
14 22G411 PLUNGER, fork rod detent 3
68 42H1077 BUSH, pivot pin 1
15 2A3647 SPRING, plunger 3
69 AHU2292 LEVER, selector release 1
16 22A387 PLUG, detent bore 2
70 22G1847 LEVER, bellcrank, lower 1
17 AED172 WASHER, sealing 2
71 42H1081 SPACER, bellcrank 2
18 22A208 GATE, gearchange 1
72 22G1848 LEVER, bellcrank, upper 1
19 88G231 SHAFT, gearchange 1
73 PWZ306 WASHER, plain 1
20 13H577 OIL SEAL, shaft 1
74 LNZ206 NUT, locking 1
21 88G222 LEVER, gearchange operating 1
22 WKN404 KEY, lever 1
23 2A3335 SCREW, operating lever to gearchange 1 Speedometer Drives
shaft 75 22A1881 PINION, 17 teeth (off white nylon) 1 1959-84, 10" road wheels (plus 12"
24 LWZ405 WASHER, shakeproof 1 wheels, 1275 GT).
25 88G224 LEVER, gearchange shaft 1 1984-94, 998 and 1275 carb (not
26 2A3335 SCREW, lever to gearchange shaft 1 France).
27 LWZ305 WASHER, locking 1 3.105:1 final drive.
28 88G223 LEVER, remote control shaft 1 DAM2905 PINION, 16 teeth (green nylon) 1 1984-92, 998.
29 2A3335 SCREW, lever to remote control shaft 1 3.444:1 final drive.
30 LWZ305 WASHER, locking 1 TXD10006 PINION, 18 teeth (red nylon) 1 1991 on, 1275 SPi (not France).
31 2A3467 BUTTON, thrust 1 Direct gearchange models. 3.211:1 final drive.
32 2A3390 SPRING, thrust button 1 Direct gearchange models. TXD10004 PINION, 15 teeth (black nylon) 1 1990 on, 1275 carb (France) and SPi
33 88G233 SHAFT, remote control 1 Direct gearchange models, 1959-68. (France), all 1275 MPi models.
34 88G553 SHAFT, remote control 1 Direct gearchange models, 1968 on. 2.762:1 final drive.
35 22A1832 SEAT, gear lever 1 Direct gearchange models, 1968 on. 76 2A3624 BUSH, steel, speedometer pinion 1
36 22A1377 BUSH, gear lever seat, rubber 1 Direct gearchange models, 1968 on. 77 DAM8488 BUSH, speedometer cable attachment 1
37 22A1378 SLEEVE, bush 1 Direct gearchange models, 1968 on. 78 2A3628 GASKET, bush 1
38 22A253 SHAFT, remote control 1 Remote gearchange models. 79 SH504071 SCREW, coarse thread, bush to housing 1
39 22G79 LEVER, bellcrank 1 Remote gearchange models. 80 LWZ304 WASHER, locking 1
40 22G259 PIN, pivot 1 81 22A862 PLATE, bush retaining 1
41 PWZ107 WASHER, plain 1 82 2A3720 GEAR, drive, 6 teeth (not paint coded) 1 1959-84, 10" road wheels (plus 12"
42 22A398 WASHER, anti-rattle A/R wheels, 1275 GT).
43 22G174 WASHER, anti-rattle A/R 1984-94, 12” road wheels, 998 and
22G175 WASHER, anti-rattle A/R 1275 carb (not France).
44 22A191 PLUNGER, reverse detent 1 3.105:1 final drive.
45 2A3647 SPRING, plunger 1 DAM6028 GEAR, drive, 7 teeth (blue paint coded) 1 1984-92, 12” road wheels, 998.
46 22A149 PLUG, detent bore 1 3.444:1 final drive.
47 AED172 WASHER, sealing 1 TXF10004 GEAR, drive, 5 teeth (red paint coded) 1 1991 on, 12” and 13” road wheels,
48 UHN305 NIPPLE, lubricating, remote control shaft 1 1275 SPi (not France).
49 2K4973 WASHER, sealing 1 3.211:1 final drive.
TXF10001 GEAR, drive, 7 teeth (yellow paint coded) 1 1990 on, 12” and 13” road wheels,
Rod Gearchange Selectors 1275 carb (France) and SPi (France),
all 1275 MPi models.
1973 On, Saloon and Estate; 1976 On, Van and Pick Up
2.762:1 final drive.
50 TSP100390 FORK, 1st and 2nd speed 1
51 TSP100400 FORK, 3rd and 4th speed 1
52 22G1854 SHAFT, selector forks 1

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Manual Gearbox - Direct and Remote Gearchanges

20 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - Direct and Remote Gearchanges
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Direct and Remote Gearchange 49 22G110 KNOB, gear lever 1 1964-73.

Direct gearchange (where the gearlever disappears through the toeboard straight into the back of the 50 22G389 BUSH, split 1 1964-73.
gearbox) was the system the Mini started with back in 1959. Its fitment was interspersed with the 51 22G292 FLANGE, retainer, nylon 1 1964-73.
remote gearchange system (where the gearlever emerged from the end of a long aluminium casting 52 22G286 SPRING 1 1964-73.
under the floor) through the 1960s to the early 1970s - by rule of thumb, more upmarket Minis got 53 22G290 RETAINER, gear lever 1 1964-73.
the remote gearchange while more basic models (i.e. lowly 850s) carried on with the direct version. 54 88G228 DISTANCE PIECE 1 1964-73.
Calling it ‘direct’ was probably a bit of a misnomer, as the nicknames of ‘Magic Wand’ and ‘Pudding 55 22G291 SCREW, retainer 2 1964-73.
Stirrer’ hinted that in practice changing gear was not always that direct... 56 LWZ505 WASHER, locking 2 1964-73.
57 2A3602 PIN, gear lever locating 1
While the direct and remote change systems are very obviously totally different, they share the same 58 LWZ304 WASHER, locking 1
gear selector mechanism inside the gearbox. From late 1968 when the gearbox went over from 3 to 4 59 22A267 LEVER, primary shaft 1
synchromesh, they shared the same differential housing too - prior to that, the direct gearchange had 60 2A3335 SCREW, lever to primary shaft 1
its own unique diff housing with a small gearchange tower on it. 61 LWZ305 WASHER, locking 1
62 8G713 PRIMARY SHAFT, remote control 1
The later rod change system (see the next section for details) required a complete redesign of the gear 63 22A250 HOUSING, remote control 1
selector mechanism. Saloons and Estates were re-engineered for rod gearchange for the 1973 model The 22A250 housing listed here attaches directly to the gearbox via four screws from underneath. The
year. Vans and Pick Ups however did not lose their direct gearchange in favour of rod change until the earliest 997cc Coopers however had a housing which attached from the sides, in a similar fashion to the
end of 1975. Austin/Morris 1100 saloon of the period, but without the rubber ‘sandwich’ mounting used on those cars.
This side-attached remote housing is not referred to in any of the factory parts catalogues, but - guess
Direct Gearchange what - we have some still in stock at time of writing. Please phone for details.
1959-68
1 22A91 GEAR LEVER, straight 1 1959-61. 64 22A271 PLUG, gear lever seat access 1
2 88G232 GEAR LEVER, cranked 1 1961-68. 65 22A285 PLUG, rubber 1
3 2A3383 KNOB, gear lever 1 1959-64. 66 22A1373 PAD, remote to gearbox case 1
4 53K1722 NUT, locking knob 1 1959-64. 67 SH506091 SCREW, coarse thread, short, remote to 2
5 22G110 KNOB, gear lever 1 1964-68. gearbox case
6 22A418 COVER, gear lever seat 1 68 SH506281 SCREW, coarse thread, long, remote to 2
7 22A419 GAITER, gear lever 1 gearbox case
8 22A394 GASKET, gear lever seat cover 1 69 LWZ306 WASHER, locking 4
9 SH605051 SCREW, coarse thread, cover retaining 2 70 22A84 PLUNGER, control shaft damping 1
10 LWZ305 WASHER, locking 2 71 AEG3123 SPRING, plunger 1
11 2A3602 PIN, gearlever locating 1 72 22A85 CAP, plunger and spring retaining 1
12 LWZ304 WASHER, locking 1 73 AEG3122 WASHER, cap 1
13 22A305 COVER, gearchange, differential cover 1 1959-62; cone synchro gearboxes. 74 14A9941 GAITER, gearlever, domed 1 1961-64.
22A516 COVER, gearchange, differential cover 1 1962-68; baulk ring synchro gearboxes. 75 22A608 GAITER, gearlever, convoluted 1 1964-73.
14 SH504051 SCREW, coarse, cover to differential cover 4 76 14A9942 PLATE, gearlever gaiter to floor 1
15 LWZ304 WASHER, locking 4 77 36052Z SCREW, plate to floor 4
16 22A84 PLUNGER, anti-rattle, gear lever 1 78 21A956 MOUNTING, rubber, remote control 1
17 AEG3123 SPRING, plunger 1 79 SH505061 SCREW, mounting to remote 2
18 22A85 CAP, plunger and spring retaining 1 80 LWZ205 WASHER, locking 2
19 AEG3122 WASHER, cap 1 81 21A745 BRACKET, mounting to floor 1
20 14A6860 GAITER, gear lever 1 82 FNZ106 NUT, mounting to bracket 1
21 14A6861 PLATE, gear lever gaiter to floor 1 83 LWZ306 WASHER, locking 1
22 36052Z SCREW, self tapping, plate to floor 4 84 PWZ206 WASHER, plain, large 1
85 SH605061 SCREW, bracket to floor 3
Direct Gearchange 86 53K3439 WASHER, ‘D’ 3
1968-73 Saloons 87 PWZ105 WASHER, plain 3
1968-75 Vans and Pick Ups 88 LWZ205 WASHER, locking 3
23 22A1382 GEAR LEVER 1 89 FNZ105 NUT 3
24 22G110 KNOB, gear lever 1 90 GAE131 SWITCH, reversing lights 1
25 22A1380 GAITER, gear lever 1 91 2K7914 WASHER, fibre, switch spacing A/R
26 22A1381 RING, gaiter retaining 1
27 22A1717 COVER, gear lever seat 1 Remote Gearchange Quickshift Kit
28 SH506061 SCREW, coarse thread, cover retaining 4 Available as an easy-to-fit conversion for 1964-73 remote gearchanges, the quickshift drastically cuts the
29 LWZ306 WASHER, locking 4 truck-like distance between gears, making gearchanges a fast, efficient pleasure instead of a work-out for
30 22A285 PLUG, rubber 1 your arm! Engineered with great integrity by Kent Auto Developments, the kit includes a new, chromed
31 22A1832 SEAT, gear lever 1 gear lever and bush, revised nylon retainer flange and longer retainer screws.
32 22A1377 BUSH, gear lever seat, rubber 1 92 1013218 QUICKSHIFT KIT 1 1964-73.
33 22A1378 SLEEVE, bush 1
34 14A6860 GAITER, gear lever 1 Accessory Gear Lever Knobs
35 14A6861 PLATE, gear lever gaiter to floor 1 Accessory Mini gear lever knobs are available from Somerford Mini to spruce up your gear lever,
36 36052Z SCREW, self tapping, plate to floor 4 providing a smart alternative to the often basic and frequently unavailable original knobs. Please order
by selecting the relevant part number for leather, wood or burr walnut finish, and then quote in your
Remote Gearchange order the insert badge you require; you can choose from the following:
1961-73 ‘Mini’ (with side view of car)
37 22A269 GEAR LEVER 1 1961-64. Mini winged logo
38 2A3383 KNOB, gear lever 1 1961-64. ‘Cooper’
39 53K1722 NUT, locking knob 1 1961-64. Mini Cooper laurel wreath
40 22G158 BUTTON, thrust 1 1961-64. ‘GT’
41 22G159 SPRING, thrust button 1 1961-64. Union flag
42 22A391 RETAINER, gear lever 1 1961-64. Chequered flags
43 22A394 GASKET, retainer 1 1961-64. Skull and crossbones (hmm... nice!)
44 22A392 FLANGE, retainer, nylon 1 1961-64.
45 22A393 O RING 1 1961-64. 93 BG2702 KNOB, gear lever, black leather 1
46 SH505071 SCREW, coarse thread, retainer to remote 2 1961-64. 94 BG2602 KNOB, gear lever, wood 1
47 LWZ305 WASHER, locking 2 1961-64. BWGK KNOB, gear lever, burr walnut 1
48 22G1190 GEAR LEVER, chrome 1 1964-73.
22A1586 GEAR LEVER, black 1 1964-73.

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Manual Gearbox - Rod Gearchange

22 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Manual Gearbox - Rod Gearchange
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Rod Gearchange 32 22A1936 ROD, steady, gear lever housing 1 1973-85.

DAM5067 ROD, steady, gear lever housing 1 1985-92, not 1990 on, 1275.
Introduced for 1973 on Mini Saloons and Estates and for 1976 on Vans and Pick Ups, the rod change
UKN10032 ROD, steady, gear lever housing 1 1990 on, 1275.
system was simpler (kept the production engineers happy) and therefore cheaper (happy accountants),
33 13H7286 BUSH, Metalastic, steady rod to gearbox 1
more robust (happy owners) and easier to use (ditto) than the previous choice of direct or remote
case
gearchange. The ‘modified Mini’ fraternity mourned the loss of positive location offered by the outgoing
34 BT605161 BOLT, steady rod to bush 1
remote system’s beefy casting, but soon welcomed the extra space inside the gearbox case which just
35 LNZ505 NUT, nyloc, thin 1
about allowed the dream of a five speed Mini gearbox conversion to become reality.
36 PWZ105 WASHER, plain 1
37 LNZ508 NUT, nyloc, thin, steady rod to gear lever 1
The success of the rod change gearbox led to it being used virtually without modification for the last
housing
27 years of the Mini’s 41 year production life.
38 PWZ108 WASHER, plain 1
39 GAE191 SWITCH, reversing lights 1
1 22A1932 GEAR LEVER 1 1973-96.
40 22A1613 NUT, locking reversing light switch 1
UKE100790 GEAR LEVER 1 1997 on.
41 CZH4278 GAITER, gearlever 1 Use when leather gaiter not fitted.
2 22G2316 KNOB, gear lever, Bakerlite 1 1973-80.
42 PAM5130 GAITER, gearlever, inner 1 Use when leather gaiter fitted.
3 22G2319 KNOB, gear lever, wood 1 1979, Mini Special.
43 FJL10016 GAITER, gearlever, outer, leather, black 1
4 DAM4440 KNOB, gear lever, nylon with clear plastic 1 1980-85.
and red
insert
The leather gaiter is also supplied in other colour and bright finisher styles to match the interior trim of
5 UKJ10005 KNOB, gear lever, nylon with clear plastic 1 1985-96.
later 1990s models. Please contact us for details of availability.
insert
6 UKJ100220 KNOB, gear lever, wood 1 1993-96, certain limited editions.
44 JPC6519 INSULATION, gearlever aperture 1 Use when leather gaiter fitted.
7 UKJ100410PMA KNOB, gear lever, leather, Black 1 1997 on.
45 FJN10003 PLATE, gearlever gaiter to floor 1
UKJ100410SMK KNOB, gear lever, leather, Light Stone 1 1997 on.
46 PTZ1006 SCREW, plate to floor 4
Beige
UKJ100230CEP KNOB, gear lever, leather, Red 1 1997 on, Classic Leather Option.
Between 1985 and 1992, Minis bound for Germany were equipped with a vacuum advance cut-out
UKJ100230HDZ KNOB, gear lever, leather, Porcelain Green 1 1997 on, Classic Leather Option.
solenoid, operated by a switch on the gearchange. This naturally necessitated the use of several modified
UKJ100230JCH KNOB, gear lever, leather, Prussian Blue 1 1997 on, Classic Leather Option.
or new gearchange components. Only those that differ from standard are listed below:
UKJ100410HDC KNOB, gear lever, leather, County Green 1 1998, Cooper Sports limited edition.
47 DAM8066 HOUSING, gear lever 1 1985-88; Germany, without brake servo.
UKJ100610PMA KNOB, gear lever, leather, Black 1 1998-99, Paul Smith, Mini 40 and
48 DAM6328 COVER, lower, housing 1 1985-88; Germany, without brake servo.
John Cooper limited editions.
49 DAM6143 BRACKET, gear lever housing 1 1985-88; Germany, without brake servo.
2000, Seven, Knightsbridge and Cooper.
50 SH604041 SCREW, bracket to housing 3 1985-88; Germany, without brake servo.
UKJ100610SMK KNOB, gear lever, leather, Light Stone 1 1999, Mini 40.
51 LWZ404 WASHER, shakeproof 3 1985-88; Germany, without brake servo.
Beige
52 DAM6049 ROD, extension support 1 1985-88; Germany, without brake servo.
8 UKJ100950MDC KNOB, gear lever, alloy 1 2000, Cooper Sport.
53 DAM8618 HOUSING, gear lever 1 1988-92; Germany, with brake servo.
9 22G1434 RETAINER, gear lever 1
54 DAM8623 COVER, lower, housing 1 1988-92; Germany, with brake servo.
10 DAM2670 PIN, gear lever retaining, long 1
55 DAM8604 BRACKET, gear lever housing 1 1988-92; Germany, with brake servo.
11 22G2277 PIN, gear lever retaining, short 1
56 SH604041 SCREW, bracket to housing 5 1988-92; Germany, with brake servo.
12 DAM3670 HOUSING, gear lever 1 Includes gear lever retaining pins and
57 LWZ404 WASHER, shakeproof 5 1988-92; Germany, with brake servo.
lower bushes.
58 DAM8587 BODY, 4th gear switch 1 1988-92; Germany, with brake servo.
13 42H1214 BUSH, housing, lower 2
59 DAM8592 SEAL, gear lever housing, front 1 1988-92; Germany, with brake servo.
14 DAM8621 COVER, lower, housing 1
60 DAM8591 SEAL, gear lever housing, rear 1 1988-92; Germany, with brake servo.
15 22G2026 BRACKET, housing to mounting rubbers 1
61 NY108041 NUT, nyloc 2 1988-92; Germany, with brake servo.
16 BT606281 BOLT, bracket to housing 1
62 DAM8588 WASHER, sealing, special 2 1988-92; Germany, with brake servo.
17 LNZ106 NUT, nyloc 1
63 DAM8599 ROD, gear change 1 1988-92; Germany, with brake servo.
18 22G2205 MOUNTING, rubber 2
64 ADU5066 SWITCH, gearbox, 4th gear, solenoid valve 1
19 FNZ105 NUT 2
operating
20 LWZ205 WASHER, locking 2
21 22G2792 EXTENSION, gearchange rod 1
Rod Gearchange Quickshift Kit
22 42H1199 ROD, extension support 1
Available as an easy-to-fit conversion for all rod change Minis, the quickshift drastically cuts the truck-like
23 22G1930 ROD, gear change 1 1973-92; not 1990 on, 1275.
distance between gears, making gearchanges a fast, efficient pleasure instead of a work-out for your arm!
UKN10023 ROD, gear change 1 1990 on, 1275.
Engineered with great integrity by Kent Auto Developments, the kit includes a new, chromed gear lever
24 42H1116 COUPLING, gear change rod to selector 1
and bush, plus a revised retainer assembly.
shaft
65 1013216 QUICKSHIFT KIT 1
25 RPS1416 ROLL PIN, rod and coupling securing 3
26 AHU1672 OIL SEAL, selector shaft, in differential 1
cover Accessory Gear Lever Knobs
27 DAM7764 BUSH, selector shaft 1 1973-85 approx.; replace with SSK001 Accessory Mini gear lever knobs are available from Somerford Mini to spruce up your gear lever,
selector oil seal kit. providing a smart alternative to the often basic and frequently unavailable original knobs. Please order
28 DAM8706 BUSH, aluminium, selector shaft 1 1985 approx. on (improved design). by selecting the relevant part number for leather, wood or burr walnut finish, and then quote in your
29 CDU1563 O RING, selector shaft 1 1985 approx. on (improved design). order the insert badge you require; you can choose from the following:
30 DAM3022 GAITER, selector shaft 1 ‘Mini’ (with side view of car)
Selector shaft oil seal failure was always a problem on rod gearchange Minis (as any late-model Mini Mini winged logo
owner with oil drips on their garage floor will know). The most common remedy effected by owners in ‘Cooper’
the past was to put two oil seals one behind the other on the selector shaft (there’s just enough space Mini Cooper laurel wreath
to do so), the outer one of the two acting both as a secondary seal and also as a secondary shield ‘GT’
behind the gaiter, protecting the inner seal from under-body muck and grit. Most importantly, the Union flag
second seal helped to support the selector shaft and hold it in alignment in the gearbox casing. Chequered flags
Skull and crossbones (hmm... nice!)
Factory engineers finally came up with a remedy in 1985, fitting a modified selector shaft bush with a
new O ring to improve the selector shaft alignment. We of course supply all these parts separately, but 66 BG2702 KNOB, gear lever, black leather 1
we’ve also put them together as an easy-to-buy, easy-to-fit kit for the owner to modify a pre-1985 Mini 67 BG2602 KNOB, gear lever, wood 1
or repair a later model. BWGK KNOB, gear lever, burr walnut 1
31 SSK001 SELECTOR OIL SEAL KIT 1 Includes oil seal, gaiter and improved
bush and O ring.

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Automatic Transmission - Torque Converter and Housing

24 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Automatic Transmission - Torque Converter and Housing
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Torque Converter Housing Torque Converter Gear Train

1 - TORQUE CONVERTER HOUSING ASS’Y 1 Non-serviced part. Note if you have a 1965 or early 1996 Mini Automatic that the output gear train is unique and is not
2 22A1239 BEARING, idler gear (1.004" ext. dia.) 1 1965-68; fit with CCN216 circlip. itemised here. Factory advice for these models is to replace all three gears with those shown here,
13H7985 BEARING, idler gear (1 1/16" ext. dia., 1 1968-82 approx.; fit with 51K3565 together with the relevant thrust washers and shims.
3/4" int. dia.) circlip.
AHU1707 BEARING, idler gear (1 3/8" ext. dia., 1 1982 approx. on (A Plus gears); fit If you are unsure that the age of your Mini’s transmission matches the age of the car, you will need to
7/8" int. dia.) without circlip. work out whether you have pre-A Plus or A Plus output gears. A Plus gears were introduced on the
As happened with Mini manual gearboxes at similar dates, the idler gear shaft diameter (i.e. idler gear Mini round about 1982 (at different times on different models...), and have a sharper tooth angle and
bearing internal diameter) and the bearing seat diameter in the torque converter housing (idler gear different pitch making them quieter than, but definitely not interchangeable with, the earlier gears. A
bearing external diameter) changed a couple of times. To be safe, measure the internal and external Plus gears can be identified by the presence of a circumferential groove in the centre of the teeth.
diameters of your bearing before ordering. Note that the idler gear thrust washers, listed later on this
page, also changed to 7/8” internal diameter when the AHU1707 bearing arrived around 1982. 37 22A1064 PRIMARY GEAR ASS’Y, with bushes 1 1965-82 approx.
DAM5713 PRIMARY GEAR ASS’Y, with bushes 1 1982 approx. to 1992; A Plus gears,
3 CCN216 CIRCLIP, bearing 1 1965-68. 998 models.
51K3565 CIRCLIP, bearing 1 1968-82. DAM9374 PRIMARY GEAR ASS’Y, with bushes 1 1992 on; A Plus gears, 1275 models.
4 AAU1365 BEARING, input gear 1 38 22A1066 BUSH, primary gear, front 1 1965-92; 848 and 998 models.
5 22A661 RETAINER, bearing 1 DAM8889 BUSH, primary gear, front 1 1992 on; 1275 models.
6 22A784 OIL SEAL, primary gear 1 39 22G109 BUSH, primary gear, rear 1 ‘Top hat’ bush.
7 22A973 COVER, engine oil pump 1 Once fitted, the primary gear bushes must be machined to ensure alignment with each other. Confusion
8 2K8161 PLUG, core, torque converter housing 1 often reigns over the convention for naming primary gear bushes. Which should be called the front bush
9 22A974 TUBE, dipstick 1 1965-96. and which should be the rear? The answer is the bush closer to the front of the engine (i.e. the water
LQN100830 TUBE, dipstick 1 1997 on (Japan). pump end) is the front bush and the bush on the torque converter end (the ‘top hat’ bush) is the rear
10 22A750 DIPSTICK ASSEMBLY 1 1965-85. bush.
11 DAM7599 DIPSTICK ASSEMBLY 1 1985-96.
LQM100700 DIPSTICK ASSEMBLY 1 1997 on (Japan). 40 22A321 WASHER, thrust, primary gear, front, 1 1965-92; 848 and 998 models.
12 AEC671 WASHER, rubber, dipstick 1 1965-85; included in 22A750 dipstick 0.110-0.112" (2.79-2.84mm)
assembly. 22A322 WASHER, thrust, primary gear, front, 1 1965-92; 848 and 998 models.
13 22A1084 PLUG, housing 1 0.112-0.114" (2.84-2.89mm)
14 22A1898 DISTANCE PIECE, starter motor to housing 1 If required; 1970 approx. to 1985. 22A323 WASHER, thrust, primary gear, front, 1 1965-92; 848 and 998 models.
15 GUG705684GM GASKET, housing to cylinder block and 1 0.114-0.116" (2.89-2.94mm)
transmission case 22A324 WASHER, thrust, primary gear, front, 1 1965-92; 848 and 998 models.
16 BH605161 BOLT, housing to cylinder block, short 3 0.116-0.118" (2.94-2.99mm)
17 BH605181 BOLT, housing to cylinder block, long 2 1965-90. 22A450 WASHER, thrust, primary gear, front, 1 1965-92; 848 and 998 models.
BH605201 BOLT, housing to cylinder block, long 2 1990 on. 0.118-0.120" (2.99-3.04mm)
18 SH605071 SCREW, housing to cylinder block 2 DAM6490 WASHER, thrust, primary gear, front, 1 1992 on; 1275 models.
19 LWZ305 WASHER, locking 6 0.112-0.114" (2.84-2.89mm)
20 12B63 WASHER, sealing 1 DAM6486 WASHER, thrust, primary gear, front, 1 1992 on; 1275 models.
For nuts, screws, washers, studs and dowels used to attach the torque converter housing to the 0.114-0.116" (2.89-2.94mm)
transmission case, please see the ‘Automatic Transmission - External’ section. DAM6487 WASHER, thrust, primary gear, front, 1 1992 on; 1275 models.
0.116-0.118" (2.94-2.99mm)
Torque Converter DAM6488 WASHER, thrust, primary gear, front, 1 1992 on; 1275 models.
0.118-0.120" (2.99-3.04mm)
21 22G1691 TORQUE CONVERTER ASSEMBLY 1 1965-70.
DAM6489 WASHER, thrust, primary gear, front, 1 1992 on; 1275 models.
DAM5085N TORQUE CONVERTER ASSEMBLY 1 1970-85; inertia starter.
0.120-0.122" (3.04-3.09mm)
DAM7564N TORQUE CONVERTER ASSEMBLY 1 1985-94; pre-engaged starter, 998
41 22A319 WASHER, thrust, primary gear, rear 1
and 1275 carburetter models.
42 88G549 RING, backing 1
TQB10007N TORQUE CONVERTER ASSEMBLY 1 1994-96; 1275 injection models.
43 22A1242 GEAR, idler, with 3/4" shaft dia. 1 1965-82 approx.
TQB100140N TORQUE CONVERTER ASSEMBLY 1 1997 on (Japan); 1275 injection
DAM5165 GEAR, idler, with 7/8" shaft dia. 1 1982 approx. on; A Plus gears.
models.
44 22A1546 WASHER, thrust, idler gear 2 1965-82 approx. (3/4” int. dia.).
The torque converter part numbers listed here are for new torque converter assemblies; reconditioned
0.130-0.131" (3.30-3.32mm)
assemblies are also available, on request - please contact us for details.
22A1545 WASHER, thrust, idler gear 2 1965-82 approx. (3/4” int. dia.).
0.132-0.133" (3.35-3.37mm)
22 22G2613 RING GEAR, starter motor 1 Included in torque converter assembly;
22A1547 WASHER, thrust, idler gear 2 1965-82 approx. (3/4” int. dia.).
inertia starter.
0.134-0.135" (3.40-3.42mm)
DAM7518 RING GEAR, starter motor 1 Included in torque converter assembly;
22A1548 WASHER, thrust, idler gear 2 1965-82 approx. (3/4” int. dia.).
pre-engaged starter.
0.136-0.137" (3.45-3.47mm)
23 27H8800 PLUG, drain 2 Included in torque converter assembly.
22A1549 WASHER, thrust, idler gear 2 1965-82 approx. (3/4” int. dia.).
24 27H8803 WASHER, sealing 2 Included in torque converter assembly.
0.138-0.139" (3.50-3.53mm)
25 27H8801 BOLT 6 Included in torque converter assembly.
DAM4822 WASHER, thrust, idler gear 2 1982 approx. on, A Plus gears
26 27H8804 LOCK TAB, torque converter bolt 3 Included in torque converter assembly.
0.132-0.133" (3.35-3.37mm) (7/8” int. dia.).
27 22A1158 SCREW, torque converter to crankshaft 1
DAM4823 WASHER, thrust, idler gear 2 1982 approx. on, A Plus gears
28 22A1155 LOCK TAB, screw 1
0.134-0.135" (3.40-3.42mm) (7/8” int. dia.).
29 22A1159 KEY, torque converter to crankshaft 1
DAM4824 WASHER, thrust, idler gear 2 1982 approx. on, A Plus gears
30 22G1022 COVER, torque converter 1 1965-70.
0.136-0.137" (3.45-3.47mm) (7/8” int. dia.).
22G1580 COVER, torque converter 1 1970-94; 998 and 1275 carburetter
DAM4825 WASHER, thrust, idler gear 2 1982 approx. on, A Plus gears
models.
0.138-0.139" (3.50-3.53mm) (7/8” int. dia.).
TGL10008 COVER, torque converter 1 1994 on; 1275 injection models.
45 22A1265 GEAR, input 1 1965-82 approx.
31 22A1114 PLUG, cover 1
DAM5164 GEAR, input 1 1982 approx. on; A Plus gears.
32 SH605081 SCREW, cover to torque converter housing 5
46 22A1266 SHIM, input gear, 0.003" (0.076mm) A/R
33 LWZ305 WASHER, locking 5
22A1267 SHIM, input gear, 0.012" (0.305mm) A/R
34 FNZ105 NUT 5
47 22A624 WASHER, abutment 1
35 TYG10007 BOLT, dowel, cover to torque converter 2 1994 on; 1275 injection models.
48 510618A NUT, nyloc, input gear 1
housing
36 22A1492 GROMMET, cover to torque converter 1 1970 on.
housing

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Automatic Transmission - Transmission Components

26 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Automatic Transmission - Transmission Components
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Rebuilt or Repaired Transmission Assemblies 51 27H7716 SCREW, housing to auxiliary pump cover 2
We do not offer a rebuild or repair service for automatic transmissions, other than for superficial 52 LWZ504 WASHER, shakeproof 2
repairs not involving the internal workings of the transmission, because of the cost of the necessary 53 22A1881 PINION, 17 teeth (off white nylon) 1 1965-82; 848/998 models with 10” wheels.
specialist equipment and the relatively few numbers of customers for automatic transmission work. DAM2905 PINION, 16 teeth (green nylon) 1 1982-84; 998 models with 10" wheels.
TXD10006 PINION, 18 teeth (red nylon) 1 1984-92; 998 models with 12" wheels.
We advise customers who require rebuilds or repairs to deal directly with an automatic transmission TNB10003 PINION, 15 teeth (blue nylon) 1 1992 on; 1275 models with 12" wheels.
specialist - we can point you in the right direction, if required. We should also mention that we carry 54 2A3624 BUSH, steel, speedometer pinion 1
out automatic to manual power unit transplants in our workshops - automatic engines are unique and 55 DAM8488 BUSH, speedometer cable attachment 1
will not fit a manual gearbox, so both engine and transmission have to be changed. This apparently 56 2A3628 GASKET, bush 1
drastic measure actually frequently represents a very cost-effective way to get your Mini back up and 57 SH504071 SCREW, coarse thread, bush to housing 1
running when otherwise faced with huge bills for automatic transmission repair. 58 LWZ304 WASHER, locking 1
59 22A862 PLATE, bush retaining 1
As a result, we do not hold comprehensive stocks of internal components for automatic transmissions. 60 27H7713 GEAR, drive, 5 teeth (not paint coded) 1 1965-92; 848 and 998 models.
Instead we limit ourselves to parts which by our own experience we consider may be fitted successfully TNB10006 GEAR, drive, 7 teeth (not paint coded) 1 1992 on; 1275 models.
by our customers - and even then, sometimes only by the more experienced ones. As always, though, if
there’s anything else you require, please contact us and if it’s available we will obtain it for you. Cylinder Block Attachment
61 GUG106SS GASKET SET, transmission case to block 1 1965-96.
Differential Housing Attachment GUG703049SG GASKET SET, transmission case to block 1 1997 on (Japan).
1 22A1012 GASKET, transmission case to housing, upper 1 1965-73; for ‘Hardy Spicer’ drive shafts. 62 AHU1959 SEAL, oil, front main bearing cap 1 ‘Half Moon’ seal.
GUG705571GM GASKET, transmission case to housing, upper 1 1973 on; for ‘pot joint’ drive shafts. 63 LUE10003 O RING, transmission case to block 1
2 22A1011 GASKET, transmission case to housing, lower 1 1965-73; for ‘Hardy Spicer’ drive shafts.
GUG705572GM GASKET, transmission case to housing, lower 1 1973 on; for ‘pot joint’ drive shafts. 1965-92, 848 and 998 Models
3 22A153 DOWEL, transmission case to housing 2 64 12H1824 DOWEL, transmission case to block 2
4 22A691 PEG, oil seal housing 1 65 FHS2409 STUD, transmission case to block, short 1
5 22A1044 STUD, transmission case to housing 1 FHS2412 STUD, transmission case to block, long 5
6 22A1045 STUD, transmission case to housing 4 66 FNZ504 NUT 6
7 22A1046 STUD, transmission case to housing 2 67 LWZ304 WASHER, locking 6
8 22A1041 STUD, transmission case to housing 1 68 SH604071 SCREW, transmission case to block 6
9 22A1043 STUD, transmission case to housing 3 69 LWZ304 WASHER, locking 6
10 FNZ506 NUT 4
11 FNZ505 NUT 7 1992 On, 1275 Models
12 LWZ305 WASHER, locking 7 70 22H983 DOWEL, transmission case to block 1
13 22A690 LOCK TAB, transmission case to housing, RH 1 71 FHS2409 STUD, transmission case to block, short 5
14 22A692 LOCK TAB, transmission case to housing, LH 1 FHS2412 STUD, transmission case to block, long 1
72 FNZ504 NUT 6
Torque Converter Housing Attachment 73 LWZ304 WASHER, locking 6
15 22A1689 GASKET, transmission case to housing 1 1965-73; for ‘Hardy Spicer’ drive shafts. 74 SH604071 SCREW, transmission case to block 6
GUG705684GM GASKET, transmission case to housing 1 1973 on; for ‘pot joint’ drive shafts. 75 LWZ304 WASHER, locking 6
16 22A97 DOWEL, transmission case to housing 2 76 BH604141 BOLT, dowel 1
17 53K547 STUD, transmission case to housing, short 6 77 12A1150 COLLAR, dowel bolt 1
18 22A963 STUD, transmission case to housing, long 4 78 PWZ104 WASHER, plain 1
19 FNZ505 NUT 10/11 Qty. increases when screw not used. 79 FNZ104 NUT 1
20 SH505101 SCREW, coarse thread, case to housing 1 If fitted.
21 LWZ305 WASHER, locking 11 Transmission Fittings
22 BH505181 BOLT, coarse thread, case to housing 2 1985 on. 80 GEG805 GASKET SET, transmission, ‘Hardy Spicer’ type1 1965-73; includes all gaskets and seals.
For screws, bolts and washers used to attach the torque converter housing to the cylinder block, please GUG708003TS GASKET SET, transmission, ‘pot joint’ type 1 1973-96; includes all gaskets and seals.
see the ‘Automatic Transmission - Torque Converter’ section. GUG708015TS GASKET SET, transmission 1 1997 on (Japan); incl. all gaskets and seals.
81 88G302 BEARING, idler gear, 1.004" ext. dia. 1 1965-68; fit with CCN216 circlip.
Front Cover Attachment 13H7848 BEARING, idler gear, 1 1/16" ext. dia. 1 1968-82 approx.; fit with 51K3565 circlip.
23 22A1487 FRONT COVER, transmission 1 1965-92; 848 and 998 models. AHU1707 BEARING, idler gear, 1 3/8" ext. dia. 1 1982 approx. on (A Plus); fit without circlip.
24 22A1334 PIPE, valve block to front cover 1 Included in 22A1487 front cover. 82 CCN216 CIRCLIP, bearing 1 1965-68.
25 22A1557 O RING, pipe 1 Included in 22A1487 front cover. 51K3565 CIRCLIP, bearing 1 1968-82.
26 DAM5246 FRONT COVER, transmission 1 1992 on; 1275 models. 83 DAM7335 PLUG, drain, magnetic 1
27 22A1334 PIPE, valve block to front cover 1 Included in DAM5246 front cover. 84 AED172 WASHER, sealing, drain plug 1
28 22A1557 O RING, pipe 1 Included in DAM5246 front cover. 85 22G1679 VALVE, low pressure 1 1965-82.
29 DAM4775 LEVER, bell crank 1 Included in DAM5246 front cover. DAM4738 VALVE, low pressure 1 1982-85.
30 DAM3967 PIN, pivot 1 Included in DAM5246 front cover. ADU6491 VALVE, low pressure 1 1985 on.
31 TYC100110 CIRCLIP, lever to pivot pin 1 Included in DAM5246 front cover. BAU2303 REPAIR KIT, low pressure valve 1 1985 on.
32 TGY10001 GUARD, inhibitor switch 1 1992 on; 1275 models. 86 GUG705568GM GASKET, valve to torque converter housing 1
33 SF504041 SCREW, guard to front cover 1 1992 on; 1275 models. 87 SH504061 SCREW, coarse thread, valve to housing 5
34 GUG705562GM GASKET, front cover to transmission case 1 88 LWZ204 WASHER, locking 5
35 SH505091 SCREW, coarse thread, cover to case 15 1965-92; 848 and 998 models. 89 22A1570 STRAINER, oil 1
36 LWZ205 WASHER, locking 15 1965-92; 848 and 998 models. 90 22A1565 SEAL, oil strainer to pick up pipe 1
37 DAM7754 SCREW, flanged, cover to case 15 1992 on; 1275 models. 91 22A1171 PIPE, oil pick up 1 1965-73; for ‘Hardy Spicer’ drive shafts.
38 BH506221 BOLT, coarse thread, cover to case 2 DAM8344 PIPE, oil pick up 1 1973 on; for ‘pot joint’ drive shafts.
39 LWZ306 WASHER, locking 2 92 LUE10003 O RING, pick up pipe 1
40 GUG705552GM GASKET, oil filter head to front cover 1 93 22G792 PIPE, oil, valve block to adaptor 1
41 22A1001 O RING, oil filter head to front cover 2 If required. 94 AWN107 WASHER, curved, adaptor pipe 1
For the engine oil filter and filter head, please see the engine catalogue pages. 95 22A1199 SEAL, oil, rubber 1
96 LUE10003 O RING, oil pipe 1
Auxiliary Pump Cover Attachment 97 DAM9051 CONTROL ASSEMBLY, kickdown 1
42 88G498 GASKET, transmission case to cover 1 1965-73; for ‘Hardy Spicer’ drive shafts. 98 27H8422 E CLIP, kickdown control bolt 1 Included in kickdown control assembly.
GUG705683GM GASKET, transmission case to cover 1 1973 on; for ‘pot joint’ drive shafts. 99 27H7738 CLIP, control rod 1 Included in kickdown control assembly.
43 22A13 DOWEL, transmission case to cover 2 100 GUG705570GM GASKET, control to transmission case 1
44 CHS2511 STUD, transmission case to cover, short 1 101 SH504061 SCREW, coarse thread, control to case 2
45 CHS2512 STUD, transmission case to cover, medium 8 102 LWZ304 WASHER, locking 2
46 CHS2516 STUD, transmission case to cover, long 2 103 PWZ104 WASHER, plain 2
47 FNZ505 NUT 11 104 22A975 ROD, valve operating 1 1965-71.
48 LWZ305 WASHER, locking 11 22A1690 ROD, valve operating 1 1971-92; 848 and 998 models.
DAM5226 ROD, valve operating 1 1992 on; 1275 models.
Speedometer Drive 105 22A978 SEAL, oil, operating rod 1 1965-71; fit with 22A977 retaining cup.
49 27H7715 HOUSING, speedometer drive 1 1965-92; 848 and 998 models. 13H6585 SEAL, oil, operating rod 1 1971 on; fit with DAM9317 retaining clip.
TJF10001 HOUSING, speedometer drive 1 1992 on; 1275 models. 106 22A977 CUP, seal and fork end gaiter retaining 1 1965-71.
50 27H7714 GASKET, housing to auxiliary pump cover 1 DAM9317 CLIP, seal retaining 1 1971 on.

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Automatic Transmission - Gearchange Controls

28 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Automatic Transmission - Gearchange Controls
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Automatic Transmission Controls 64 LWZ204 WASHER, locking 1

65 FNZ104 NUT 1
1965-92, 850 and 1000
66 22A1703 BRACKET, valve operating rod to lever 1
1 22A1118 GEAR LEVER 1 1965-69.
67 FNZ104 NUT 1
2 22A1077 KNOB, gear lever 1 1965-69.
68 LWZ204 WASHER, locking 1
3 22A1575 GEAR LEVER 1 1969-82.
69 BH604111 BOLT, bracket to lever 1
DAM5777 GEAR LEVER 1 1982-92.
70 LWZ204 WASHER, locking 1
4 22A1501 KNOB, gear lever 1 1969-92.
71 22A1808 COLLAR, spacing bracket 1
5 53K1722 NUT, locking, gear lever knob 1 1969-92.
72 22A1695 FORK END, selector cable 1
6 22A1577 SLEEVE, gear lever, reverse baulk 1 1969-92.
73 ANZ103 NUT, locking selector cable fork end 2
7 AHC197 SPRING, return, reverse baulk 1 1969-92.
74 WL700101 WASHER, locking 1
8 13H5837 CIRCLIP 1 1969-92.
75 SH604081 SCREW, fork end to lever 1
9 AHC196 WASHER, special 1 1969-92.
76 LWZ204 WASHER, locking 1
10 54K1722 NUT, locking, reverse baulk sleeve 1 1969-92.
77 FNZ504 NUT 1
11 22G461 HOUSING, gear selector 1
12 PMZ412 SCREW, housing to floor 4 1965-73.
Enclosed Pressed Bell Crank Lever 1971-92
13 22A2062 PLATE, housing mounting 1 1973-92.
78 22A1697 LEVER, bell crank 1
14 22A2067 GASKET, plate 1 1973-92.
79 BH504131 BOLT, coarse thread, lever pivot 1
15 ANZ103 NUT, plate to floor 4 1973-92.
80 LWZ204 WASHER, locking 1
16 WL700101 WASHER, locking 4 1973-92.
81 22A1702 COLLAR, spacing pivot bolt 1
17 22A1068 PIVOT, gear lever 1
82 22A1703 BRACKET, valve operating rod to lever 1
18 22A941 BUSH, sliding, pivot 1
83 FNZ104 NUT 1
19 22A943 CIRCLIP, pivot 1
84 LWZ204 WASHER, locking 1
20 22A1076 RETAINER, pivot 1
85 BH604111 BOLT, bracket to lever 1
21 PMZ306 SCREW, retainer 2
86 LWZ204 WASHER, locking 1
22 WL700101 WASHER, locking 2
87 22A1695 FORK END, selector cable 1
23 ANZ103 NUT 2
88 ANZ103 NUT, locking selector cable fork end 2
24 22A1117 PLATE, gear indicator 1 1965-69.
89 WL700101 WASHER, locking 1
22A1821 PLATE, gear indicator 1 1969-73.
90 SH604081 SCREW, fork end to lever 1
22A1883 PLATE, gear indicator 1 1973-92.
91 LWZ204 WASHER, locking 1
25 RTP603 SCREW, self tapping, plate to control box 4
92 FNZ504 NUT 1
26 22G1123 CONTROL BOX 1
93 22A1704 COVER, linkage 1
27 SH504051 SCREW, coarse thread, control box to 4
94 SH505091 SCREW, coarse thread, cover securing 2
housing
95 2K2545 WASHER, locking 2
28 LWZ204 WASHER, locking 4
96 PWZ105 WASHER, plain 2
29 22A1075 SPRING, reverse gear abutment 1
30 22A1028 PLUNGER, gear selector 1 1965-82.
97 13H4007 SWITCH, gearbox, starter inhibitor and 1 1965.
DAM5780 PLUNGER, gear selector 1 1982-92.
reverse lights
31 22A2217 CABLE, gear selector 1
13H5045 SWITCH, gearbox, starter inhibitor 1 1966-92.
32 22A1146 GAITER, cable, small 1
98 GAE191 SWITCH, reversing lights 1 1966-92.
33 22A1147 GAITER, cable, large 1
99 22A1613 NUT, locking reversing light switch 1 1966-92.
34 FNZ103 NUT, cable, locking 1
35 NT604041 NUT, cable, locking 1
36 FNZ207 NUT, cable, locking 2 Automatic Transmission Controls
37 PCR507 CLIP, selector cable 1 1965-69. 1992 On, 1275
38 CP105081 CLIP, selector cable 1 1969-92. 100 DAM7535 KNOB, gear lever 1
39 22A1858 FERRULE, selector cable 1 1969-92. 101 UCB10031 GEAR SELECTOR ASSEMBLY 1
40 PTZ1004 SCREW, self tapping, clip 1 102 UCV10022 CABLE, gear selector 1 Included in selector assembly.
41 WL700101 WASHER, locking 1 103 NH105041 NUT, selector assembly to floor 4
42 DAM8711 SPACER, selector cable to subframe 1 1987-92. 104 WE105001 WASHER, locking 4
43 12A1358 BUSH, selector cable 2 105 UCJ10022PMA COVER, selector assembly, black 1
44 22A1188 DISTANCE TUBE, bush 1 DAM2319 CLIP, cover to selector assembly 4
45 22A1195 WASHER, plain 2 106 DAM4551 GEAR INDICATOR ASSEMBLY, illuminated 1
107 DAM4360 WINDOW, gear indicator 1
Forged Bell Crank Lever 1965-70 108 GLB504 BULB, gear indicator illumination 1
46 88G456 LEVER, bell crank 1 109 UCD10033 LEVER, bell crank 1
47 21A798 BUSH, bell crank lever 1 Included in lever. 110 DAM5227 PIVOT, lever 1
48 22A1160 PIVOT, lever 1 111 ADU5500 CIRCLIP, lever to pivot 1
49 22A995 WASHER, shakeproof 1 112 UEM10002 TRUNNION, selector cable to lever 1
50 22A1161 WASHER, plain 1 113 SH105101P SCREW, cable clamping 1
51 LNZ205 NUT, nyloc 1 114 DAM8362 BOBBIN, valve operating rod 1
52 22A989 FORK END, valve operating rod 1 115 FNZ104 NUT 1
53 FNZ204 NUT, locking operating rod fork end 1 116 LNZ204 NUT, nyloc 1
54 22A999 FORK END, selector cable 1 117 22A1704 COVER, linkage 1
55 ANZ103 NUT, locking selector cable fork end 2 118 SH505091 SCREW, coarse thread, cover securing 2
56 WL700101 WASHER, locking 1 119 2K2545 WASHER, locking 2
57 22A1196 CLEVIS PIN, fork ends to lever 2 120 PWZ105 WASHER, plain 2
58 PWZ104 WASHER, plain 2 121 ADU5066 SWITCH, gearbox, starter inhibitor 1
59 22A1164 GAITER, operating rod fork end 1 122 TGY10001 GUARD, inhibitor switch 1
60 22A1165 GAITER, selector cable fork end 1 123 SF504041 SCREW, guard to front cover 1
61 22A1284 GUARD, bell crank lever 1 1968-70. 124 GAE191 SWITCH, reversing lights 1
125 22A1613 NUT, locking reversing light switch 1
Exposed Pressed Bell Crank Lever 1970-71
62 22A1697 LEVER, bell crank 1
63 22A1807 PIVOT, lever 1

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Final Drive (Differential)

30 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk

 Final Drive (Differential)
No. Part No. Description Qty. Remarks No. Part No. Description Qty. Remarks

Final Drive Assembly 15 AHU1856 BEARING, differential 2

16 2A3535 SHIM, bearing, 0.002" (0.0508mm) A/R
You will need to establish several things before embarking on a rebuild of your final drive:
2A3534 SHIM, bearing, 0.003" (0.0762mm) A/R
DAM3108 SHIM, bearing, 0.006" (0.1520mm) A/R
The first thing (and the easiest) is to work out which drive shafts your Mini has. Rubber coupling (or
DAM3109 SHIM, bearing, 0.010" (0.2540mm) A/R
‘Moulton’) drive shafts were used on most Minis up until 1973. The exceptions were the Cooper S and
DAM3633 SHIM, bearing, 0.020" (0.5080mm) A/R
automatic transmission models, which used universal joint (or ‘Hardy Spicer’) drive shafts up until that
17 88G477 DISTANCE PIECE, with bush 1 Automatic transmission models; for
date. From 1973 onwards, all Minis used offset sphere (or ‘pot joint’) drive shafts. The designs of the
universal joint (‘Hardy Spicer’) shafts.
final drive output shafts and their covers depend on the drive shafts fitted. While rebuilding a final
CHM166 DISTANCE PIECE, with bush 1 Automatic transmission models; for
drive on a rubber coupling Mini, you can easily convert it to take ‘pot joint’ drive shafts if you wish by
offset sphere (‘pot joint’) drive shafts.
fitting a pair of DAM3114 output shafts and 22G2688 circlips.
18 22G421 BUSH, distance piece 1 Automatic transmission models; for
universal joint (‘Hardy Spicer’) shafts.
The final drive gear also needs to be identified. This may be achieved by counting the number of teeth
2A3538 BUSH, distance piece 1 Automatic transmission models; for
on the final drive gear and if you divide that number by the number of teeth on the corresponding
offset sphere (‘pot joint’) drive shafts.
final drive pinion in the gearbox, you’ll get the final drive ratio. If you are unsure whether the age of
your Mini’s transmission matches the age of the car, you will also need to work out whether you have
pre-A Plus or A Plus gears. A Plus gears were introduced on the Mini round about 1982 (at different Final Drive Output
times on different models...), and have a sharper tooth angle and different pitch making them quieter Rubber Coupling (‘Moulton’) Type
than, but definitely not interchangeable with, the earlier gears. Looking in the gearbox, A Plus gears can All Manual Gearbox Models Except Cooper S, 1959-73
be identified by the presence of a circumferential groove in the centre of the teeth, and the final drive 19 CHM85 COVER ASSEMBLY, with bush 2
pinion on the gearbox mainshaft is machined flush on both sides. 20 2A3538 BUSH, cover 2
21 ADU5738 OIL SEAL, cover 2
The only exception to this rule concerns cars with the 3.444:1 final drive ratio, which received A Plus 22 GUG705567GM GASKET, cover 2
final drive gears in 1979, a full 3 years before they got A Plus gearboxes. So, if you have a 3.444:1 23 SH505101 SCREW, coarse thread, cover to gearbox 10
final drive Mini with a pre-A Plus gearbox containing the larger idler gear and 1st/3rd motion shaft 24 LWZ305 WASHER, locking 10
bearings introduced in 1979, the chances are you will have A Plus final drive gears. 25 22A374 FLANGE, output 2
26 FNZ810 NUT, output flange to shaft 2
Lastly, you will need to identify your differential case. The case was redesigned in the early 1980s to 27 PWZ110 WASHER, plain 2
combat the problem of spinning pinion thrust washers wearing through it: notches were added to the 28 GCD101 RUBBER COUPLING KIT, drive shaft 2 Includes one coupling, U bolts and nuts.
case to locate anti-rotation tabs on redesigned thrust washers. QL5000 NYLON COUPLING KIT, drive shafts 1 Uprated; includes two nylon and needle
roller couplings, plus U bolts and nuts.
For those indulging in modified or competition Minis, several flavours of limited slip differential and a 29 22A132 U BOLT, coupling to shaft yokes 8
stronger cross pin differential are available as special orders; please contact us to discuss your needs. 30 LNZ205 NUT, locking 16

1 BTA145 CASE, differential 1 Use with plain pinion thrust washers. Universal Joint (‘Hardy Spicer’) Type
DAM6027 CASE, differential 1 Use with anti-rotation thrust washers. Cooper S, 1963-71; All Automatic Transmission Models, 1965-73
2 ATA7378 BUSH, differential case 1 Included in differential case. 31 22G419 COVER ASSEMBLY, with bush 2 Cooper S.
32 22G421 BUSH, cover 2 Cooper S.
Final Drive Gears, Manual Gearbox 33 AHU1082 OIL SEAL, cover 2 Cooper S.
3 22G443 GEAR, final drive, 65 teeth, 4.333:1 ratio 1 For 15 tooth 22G99 pinion. 34 GUG705567GM GASKET, cover 2 Cooper S.
22G370 GEAR, final drive, 64 teeth, 4.267:1 ratio 1 For 15 tooth 22G99 pinion. 35 SH505101 SCREW, coarse thread, cover to gearbox 10 Cooper S.
22G101 GEAR, final drive, 62 teeth, 4.133:1 ratio 1 For 15 tooth 22G99 pinion. 36 LWZ305 WASHER, locking 10 Cooper S.
22G340 GEAR, final drive, 63 teeth, 3.938:1 ratio 1 For 16 tooth 22G338 pinion. 37 88G476 COVER ASSEMBLY, with bush 2 Automatic transmission models.
22A401 GEAR, final drive, 64 teeth, 3.765:1 ratio 1 For 17 tooth 22A399 pinion. 38 22G421 BUSH, cover 2 Automatic transmission models.
22G940 GEAR, final drive, 62 teeth, 3.647:1 ratio 1 For 17 tooth 22A399 pinion. 39 AHU1082 OIL SEAL, cover 2 Automatic transmission models.
22A411 GEAR, final drive, 62 teeth, 3.444:1 ratio 1 For 18 tooth 22A413 pinion. 40 22A1612B GASKET, cover 2 Automatic transmission models.
DAM3645 GEAR, final drive, 65 teeth, 4.333:1 ratio 1 For 15 tooth DAM3647 pinion; A Plus. 41 SH505081 SCREW, coarse thread, cover to gearbox 8 Automatic transmission models.
DAM3216 GEAR, final drive, 63 teeth, 3.938:1 ratio 1 For 16 tooth DAM3218 pinion; A Plus. 42 LWZ305 WASHER, locking 8 Automatic transmission models.
DAM4779 GEAR, final drive, 64 teeth, 3.765:1 ratio 1 For 17 tooth DAM4131 pinion; A Plus. 43 22A1152 FLANGE, output, with bolts 2
DAM4162 GEAR, final drive, 62 teeth, 3.647:1 ratio 1 For 17 tooth DAM4131 pinion; A Plus. 44 22A1139 BOLT, output flange to drive shaft 8
DAM2677 GEAR, final drive, 62 teeth, 3.444:1 ratio 1 For 18 tooth DAM2679 pinion; A Plus. 45 LNZ405 NUT, locking, output flange bolt 8
DAM2806 GEAR, final drive, 61 teeth, 3.211:1 ratio 1 For 19 tooth DAM2808 pinion; A Plus. 46 22A1104 SCREW, output flange to output shaft 2
DAM6327 GEAR, final drive, 59 teeth, 3.105:1 ratio 1 For 19 tooth DAM2808 pinion; A Plus. 47 WE600101 WASHER, shakeproof 2
DAM5925 GEAR, final drive, 59 teeth, 2.950:1 ratio 1 For 20 tooth DAM5927 pinion; A Plus. 48 22A1201 WASHER, plain 2
TCB10004 GEAR, final drive, 58 teeth, 2.762:1 ratio 1 For 21 tooth TCC10001 pinion; A Plus. 49 88G493 COLLET, output flange 4
50 22A1566 RING, sealing 2
Final Drive Gears, Automatic Transmission
22A1003 GEAR, final drive, 72 teeth, 3.273:1 ratio 1 For 22 tooth 22A1300 pinion. Offset Sphere (‘Pot Joint’) Type
DAM7362 GEAR, final drive, 72 teeth, 3.273:1 ratio 1 For 22 tooth DAM7365 pinion; A Plus. All Models, 1973 On
DAM4130 GEAR, final drive, 69 teeth, 2.760:1 ratio 1 For 25 tooth DAM4128 pinion; A Plus. 51 CHM85 COVER ASSEMBLY, with bush 2 Manual gearbox models.
52 2A3538 BUSH, cover 2 Manual gearbox models.
4 ATA7378 BUSH, final drive gear 1 Included in final drive gear. 53 ADU5738 OIL SEAL, cover 2 Manual gearbox models.
5 ATA7043 BOLT, gear to differential case 6 54 GUG705567GM GASKET, cover 2 Manual gearbox models.
6 ATA7385 LOCK TAB, bolt 3 55 SH505101 SCREW, coarse thread, cover to gearbox 10 Manual gearbox models.
7 BTA154 BLOCK, thrust 1 Optional in DAM6027 differential case. 56 LWZ305 WASHER, locking 10 Manual gearbox models.
8 DAM6624 PINION, differential 2 57 CHM167 COVER ASSEMBLY, with bush 2 Automatic transmission models.
9 2A7062 WASHER, pinion thrust, plain 2 Use in BTA145 differential case. 58 2A3538 BUSH, cover 2 Automatic transmission models.
10 DAM5071 WASHER, pinion thrust, with anti-rotation 2 Use in DAM6027 differential case. 59 ADU5738 OIL SEAL, cover 2 Automatic transmission models.
tab 60 22A1612B GASKET, cover 2 Automatic transmission models.
11 22G2583 CROSS PIN, pinion 1 61 SH505081 SCREW, coarse thread, cover to gearbox 8 Automatic transmission models.
12 RPS1418 ROLL PIN, cross pin 1 62 LWZ305 WASHER, locking 8 Automatic transmission models.
13 22A373 OUTPUT SHAFT AND GEAR 2 For rubber (‘Moulton’) couplings. 63 22G2688 CIRCLIP, output shaft 2
22A1151 OUTPUT SHAFT AND GEAR 2 For universal joints (‘Hardy Spicer’). 64 GCV1102 OFFSET SPHERE C.V. JOINT ASS’Y 2 ‘Pot’ joint.
DAM3114 OUTPUT SHAFT AND GEAR 2 For offset spheres (‘pot joints’). 65 GSV1073 GAITER KIT, offset sphere joint 2 Includes one gaiter, clips and grease.
14 BTA101 WASHER, output gear thrust 2 66 AKF1457 GREASE, sachet, offset sphere joint A/R

Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk 31

Brief Mini Production History

This list is intended to assist some owners who are trying to establish year and model of their Mini. Model Years Chassis No./ Commencing
However, while the list may seem comprehensive, it isn’t. Just like everything else to do with the Mini Built VIN Prefix Chassis No./VIN
when you look at its 40 year history, to come up with every last derivative, complete with corresponding Mini Mayfair (1000) Europe Non Catalyst 1988-92 X-L2S1S 396449
chassis number (or vehicle identification number) prefix, would take several pages! However, limited Mini Mayfair (1000) Europe Catalyst 1989-92 X-L2S3S 426565
editions excepted, it details the Mini models covered by this catalogue and is a fair representation of Mini Sprite (1275) 1992-94 XN-YA 049349
models down through the years. Mini Sprite 1.3i (1275) 1994-96 XN-YA 058254
Mini Mayfair (1275) 1992-94 XN-WA 049349
It does not cover models specific to certain markets that were locally assembled (e.g. Innocenti, Authi, Mini Mayfair 1.3i (1275) 1994-96 XN-WA 058254
Cord and Belgium, South Africa and Australia assembled vehicles). It also does not include certain short- Mini Cooper (1275) RSP Limited Edition 1990 XN-CA 010001
lived niche models like the ERA Mini Turbo. Mini Cooper (1275) 1990-91 XN-CA 011651
Mini Cooper 1.3i (1275) 1991-96 XN-CA 031550
Note that earlier MkI export models were often badged ‘850’ rather than ‘Mini’ or ‘Seven’, and that the
later 1980s/1990s City models were usually known in Europe as Special and in Japan as Sprite. Mini Saloons 1997 On (Multi Point Injection or MPi, plus TBi)
Mini (1275) MPi 1997-2000 XN-WA 134455
Model Years Chassis No./ Commencing Mini (1275) TBi Japan 1997-1999 XN-WA 134455
Built VIN Prefix Chassis No./VIN Mini Cooper (1275) MPi 1997-2000 XN-CA 134455
Austin and Morris Mk I Saloons 1959-67 Mini Cooper (1275) TBi Japan 1997-1999 XN-CA 134455
Austin Seven (850) 1959-62 A-A2S7 101
Austin Mini (850) 1962-67 A-A2S7 197201 Riley and Wolseley Saloons 1961-69
Austin Seven De Luxe (850) 1959-62 A-A2S7 101 Riley Elf (850) 1961-63 R-A2S1 156851
Austin Mini De Luxe (850) 1962 A-A2S7 197021 Riley Elf Mk II (1000) 1963-66 R-A2S2 369601
Austin Super Seven (850) 1961-62 A-A2S7S 125538 Riley Elf Mk III (1000) 1966-69 R-A2S3 930221
Austin Super Mini (850) 1962 A-A2S7S 197021 Wolseley Hornet (850) 1961-63 W-A2S1 156861
Austin Mini Super De Luxe (850) 1962-64 A-A2S7S 307125 Wolseley Hornet Mk II (1000) 1963-66 W-A2S2 367151
Austin Mini De Luxe (850) 1964-67 A-A2S7 640203 Wolseley Hornet Mk III (1000) 1966-69 W-A2S3 927473
Austin Seven/Mini Cooper (997) 1961-64 C-A2S7 138301
Austin Mini Cooper (998) 1963-67 C-A2S7 486096 Mini Clubman Saloons 1969-80
Austin Mini Cooper S (1071) 1963-64 C-A2S7 384101 Mini Clubman (1000) 1969-74 X-A2S2 101
Austin Mini Cooper S (1275) 1964-67 C-A2S7 551501 Mini Clubman (1000) 1974-75 X-L2S2 101
Austin Mini Cooper S (970) 1964-65 C-A2S7 549501 Mini Clubman (1100) 1975-80 X-C2S2 258877
Morris Mini Minor (850) 1959-67 M-A2S4 101 Mini Clubman (1000 Automatic) 1975-80 X-L2S2 258877
Morris Mini Minor De Luxe (850) 1959-62 M-A2S4 101 Mini 1275 GT 1969-74 X-AD2 101
Morris Super Mini Minor (850) 1961-62 M-A2S4S 75573 Mini 1275 GT 1974-80 X-E2D2 101
Morris Mini Minor Super De Luxe (850) 1962-64 M-A2S4S 148817
Morris Mini Minor De Luxe (850) 1964-67 M-A2S4 296257 Mini Cabriolets 1991-96
Morris Mini Cooper (997) 1961-64 K-A2S4 138311 Mini Cabriolet (Lamm Design) 1991-93 XN-WB 024857
Morris Mini Cooper (998) 1963-67 K-A2S4 491251 Mini Cabriolet (Rover) 1993-96 XN-WB 061481
Morris Mini Cooper S (1071) 1963-64 K-A2S4 384101
Morris Mini Cooper S (1275) 1964-67 K-A2S4 552501 Austin and Morris Mk I Estates 1960-67
Morris Mini Cooper S (970) 1964-65 K-A2S4 550501 Austin Seven Countryman (850) 1960-62 A-AW7 19126
Austin Mini Countryman (850) 1962-67 A-AW7 197104
Austin and Morris Mk II Saloons 1967-70 Morris Mini Minor Traveller (850) 1960-67 M-AW4 19101
Austin Mini Mk II 850 1967-69 A-A2SB 1068001
Austin Mini Mk II 850 Super De Luxe 1967-69 A-A2SB 1068001 Austin and Morris Mk II Estates 1967-69
Austin Mini Mk II 1000 Super De Luxe 1967-69 A-A2SB 1068001 Austin Mini Countryman Mk II 1000 1967-69 A-AWB 1068101
Austin Mini Cooper Mk II (998) 1967-69 C-A2SB 1068151 Morris Mini Traveller Mk II 1000 1967-69 M-AW6 1068401
Austin Mini Cooper S Mk II (1275) 1967-70 C-A2SB 1068451
Morris Mini Mk II 850 1967-69 M-A2S6 507001 Mini Clubman and HL Estates 1969-82
Morris Mini Mk II 850 Super De Luxe 1967-69 M-A2S6 507001 Mini Clubman Estate (1000) 1969-74 X-A2W2 101
Morris Mini Mk II 1000 Super De Luxe 1967-69 M-A2S6 507001 Mini Clubman Estate (1000) 1974-75 X-L2W2 101
Morris Mini Cooper Mk II (998) 1967-69 K-A2S6 1068197 Mini Clubman Estate (1100) 1975-80 X-C2W2 259639
Morris Mini Cooper S Mk II (1275) 1967-70 K-A2S6 1068471 Mini Clubman Estate (1000 Automatic) 1975-80 X-L2W2 259639
Mini HL Estate (1000) 1980-82 X-L2W2 751080
Mini Mk III Saloons 1969-75
Mini 850 1969-74 X-A2S1 101 Mini Vans 1960-84
Mini 850 1974-75 X-K2S1 101 Austin Seven/Mini Van (850) 1960-69 A-AV7 12101
Mini 1000 1969-74 X-A2S1N 101 Austin Mini Van (1000) 1967-69 A-AV7 1068001
Mini 1000 1974-75 X-L2S1N 101 Morris Mini Van (850) 1960-69 M-AV4 12601
Mini Cooper S Mk III (1275) 1970-71 X-AD1 101 Morris Mini Van (1000) 1967-69 M-AV4 1068001
Mini Van (850 and 1000) 1969-74 X-AV1 101
Mini Saloons 1976-96 (‘Mk IV’ and Throttle Body Injection or TBi) Mini Van (850) 1974-79 X-KV1 101
Mini 850 1976-79 X-K2S1 340101 Mini Van (1000) 1974-79 X-LV1 101
Mini City (850) 1979-80 X-K2S1 633177 Mini 95 Van (850) 1979-84 X-KV1 126932
Mini 850 Super De Luxe 1979-80 X-K2S1N 635039 Mini 95 Van (1000) 1979-84 X-LV1 126932
Mini 1000 1976-79 X-L2S1N 340554
Mini 1000 Super 1979-80 X-L2S1N 633285 Mini Pick Ups 1961-83
Mini City (1000) 1980-82 X-L2S1O 743114 Austin Seven/Mini Pick Up (850) 1961-69 A-AU7 87551
Mini City E (1000) 1982-88 X-L2S1O 122249 Austin Mini Pick Up (1000) 1967-69 A-AU7 1068001
Mini City (1000) Non Catalyst 1988-92 X-L2S1O 396449 Morris Mini Pick Up (850) 1961-69 M-AU4 91551
Mini City (1000) Catalyst 1989-92 X-L2S3O 426565 Morris Mini Pick Up (1000) 1967-69 M-AU4 1068001
Mini HL (1000) 1980-82 X-L2S1N 743004 Mini Pick Up (850 and 1000) 1969-74 X-AU1 101
Mini HLE (1000) 1982 X-L2S1N 122249 Mini Pick Up (850) 1974-79 X-KU1 101
Mini Mayfair (1000) 1982-88 X-L2S1N 147144 Mini Pick Up (1000) 1974-79 X-LU1 101
Mini Mayfair (1000) Non Catalyst 1988-92 X-L2S1N 396449 Mini 95 Pick Up (850) 1979-80 X-KU1 25448
Mini Mayfair (1000) Catalyst 1989-92 X-L2S3N 426565 Mini 95 Pick Up (1000) 1979-83 X-LU1 25448

32 Tel. 01249 721421 Fax. 01249 721316 www.somerford-mini.co.uk