I pulled my transmission off today to change the clutch, and found that the clutch is saturated with oil because a small chunk of metal was broken out of the bell housing from inside the transmission. I was prepared to replace the output shaft seal again, but I didn't expect this. Here's a picture:

by https://www.flickr.com/photos/134214227@N03/, on Flickr

Inside that tiny hole is a single ball bearing. Does anyone have any diagrams so I can see what should be inside that space near the edge of the diff? I think some bearing came apart, perhaps broke a ball bearing, and forced a chunk of case outward.

I imagine I'll have to get another bell housing section, and since I'll be in there anyway I may as well rebuild the transmission. I just priced used transaxles, and... wow... sticker shock. So, it looks like I'll be rebuilding the transmission. I can't afford to write off the car, after all. Any ideas?

Thanks,
Scott

 

I'm not sure why it's showing two copies of the photo. The preview shows only one. Weird....

Scott

 

 

I would open up the trans to find out how it got there as we see holes exactly like that in the same place when the diff fails.
Fix the failed part then a good welder can usually fix the hole.

 

I was thinking the same thing. I started by finding the R50 Midland repair manual ( https://www.motoringalliance.com/pdf..._%20Manual.pdf ) and I can't see in any of the diagrams any component nearby that would have a ball bearing in it. My hunch is that a bearing failed, and it rattled down to that location, where it got forced into a narrow point and broke the chunk of aluminum out from the inside at that point. I'll confirm that when I open the transmission up.

I was also thinking about the best way to repair that, and if there's supposed to be no bearing or solid component behind it, then welding up the hole or drilling and tapping it and inserting a plug should work. I've got to open it up first.

After 30 years of British car ownership, it looks like I'll be repairing my first transmission. <<gulp>> Funny that overhauling an engine seems less daunting, somehow.

Scott

 

After even more study, it looks like that little ball bearing may be from a synchronizer. The only way to know for sure will be to take the thing apart, and to see if I've got a synchro finger without its ball, and perhaps a spring chopped to bits. I may well have some synchronizer rings chewed up if bits of a broken spring were knocked around as the transmission spun.

The odd thing is that even as I drove the car around, the car shifted very smoothly and crisply. It didn't feel bad at all. Mystifying....

Scott

 

I feel your pain. Since you have the biscuits box out, I would just tear into it to see what surprise treasures lie inside. I opine the Midland box contain gears made of cheese. In my mind the question is how could steel ball bearing impaled into the AL housing and emerge on the other side of the wall, with the R50 sewing machine-like engine? Bearing ***** from an IED? A vengeful neighbour? Spinning fast enough anything with substantial density becomes shrapnel. Still, it is possible with an R50 engine?

Seriously I am with you that the poor bearing ball must just found itself between the rock and a hard place, being squeezed and something less tough had to give.

 

pnwR53S, at first I thought your post was a little insensitive, but then I looked at the thread of your work on your car and I realized you've made many of the mods I've thought about making to my car. You look like a handy fellow to know. May I ask your advice from time to time? Also, it looks like you're in Oregon, perhaps in the west hills of Portland. PIR certainly looks familiar enough in many of your pics. We might be close enough to meet, perhaps at the All British Field Meet. Thanks for commenting.

Scott

 

skucera, did you open up the transmission and see what happened?
I've just heard back from the transmission shop which has mine apart to do the clutch that it wasn't the rear main seal leaking as I thought, but there is a hole in the transmission which has then leaked out fluid.
I'll be dropping by tomorrow to check out the damage.
Any more info helps. Thanks!

 

Phil, no, I never opened up that transmission. Actually, I've had a long list of projects pop up that have all been higher priority for one reason or another, and I'm finally getting to the point where I can get going on this repair this weekend. Nothing like a pandemic to allow time to stay at home on work in the garage. I pulled the tranny out from under its protective tarp and gathered the Dremel bits for surgery.

Out of curiosity, I'd love to see a picture of your hole when you get to the shop. I wonder if your failure is similar.

Good luck, and keep a stiff upper lip.

Scott