Gearbox Done

 After spending the winter rebuilding the gearbox and the clutch, I'm pleased to be finishing the job as the weather warms up.

First job, before finally closing up the gearbox is to fit the kickstart stop rubber that has been waiting on the bench for literally years. I needed to remove the metal part of the stop and reduce the 1/2" OD to about 7/16" to get the rubber to go over it. I mangled one in the process of realising that, which delayed the job by a week:

Next, when the kickstart is on and the gearchange mechanism is timed, I need to fill the gearbox. This is easier said than done as on a SQ4, the filler is hidden behind the oil pipes. Surgeon's forceps are useful to get it out:

Since the Morris K400EP grease is quite fluid, the easiest way to get the grease in is to use a syringe. This is a 250 ml syringe and you need 750 ml. It's got a flexible hose and a rigid copper pipe on the end to get the grease through the filler and into the top of the gearbox. You can fill the syringe by sucking the grease out of the tin:

Next time i do this, I'll do it warmer weather. This was hard work:

In a departure from usual practice, I've measured the oil going into the primary case - 150 ml of engine oil, to determine how much I can get in without it leaking.

I'll road test it, then see if 150 ml is too much or not enough.

Running the engine on the rear stand shows I can select all gears completely silently. It's never been as good as this: