[Healeys] Advice and guidance needed for OD reinstallation

[Bob Spidell]

Hi Michael,

I've particular interest in the jumping-out-of-gear issue as I've 
suffered it, mainly after a previous rebuild. But, the issue went away* 
after a while. I think you are absolutely correct, as any forward-aft 
movement could break the engagement of the coupling (detent springs are 
insufficient by themselves to hold the 3/4 gears in contact). Note the 
DWM 3/4 replacement says the plungers that go in  this gear are 
'unnecessary'--do you know what they're for?--but I re-installed them 
anyway. Since the 'mainshaft' is actually two pieces--first motion and 
main--any slop there would be problematic. Interesting that BMC did away 
with the bellville/shim arrangement and went to a fixed shim in the BJ8; 
a better arrangement, or just cheaper?

One 'theory' I've heard is that the orientation of the shift 
boot--nipple-up or nipple-down--can cause 4th to disengage; I don't 
remember which way can cause it and, I think the 'correct' way is in 
dispute (though period photos show nipple-down). It's been a couple 
decades, but IIRC the issue* 'went away' when I changed the orientation 
of the boot. I've found the nipple-up placement to last a bit longer, as 
new rubber components are often pretty crappy.

bs

On 8/28/2025 8:14 AM, Michael Salter wrote:
> Bob, some years ago I was asked to resolve a "jumping out of 4th gear 
> on overrun" issue in a late BJ8 gearbox and discovered that the shims 
> for both the 1st and 3rd shaft bearings were missing entirely however 
> there was also some wear on the internal teeth on both sides of the 
> 3/4 coupling sleeve.
> I replaced the coupling sleeve and the shims on both bearings which 
> resolved the problem.
> My conclusion was that the missing shims were the primary cause of the 
> problem and that the wear on the sleeve was caused by the axial 
> movement of the shaft(s) ; however that was supposition on my part and 
> I would love to hear more about this subject.
>
> M
>
> On Thu, Aug 28, 2025 at 10:39 AM Bob Spidell via Healeys 
> <healeys at autox.team.net> wrote:
>
>     When I read this I thought "OMG, I didn't put these in when I did
>     a gearbox/OD rebuild a few years ago, is that what causes the
>     notorious jumping-out-of-fourth problem?!" So I checked my parts
>     catalog--aka the Moss catalog--and didn't see them listed in the
>     OD sections, but I did find them in the 'Internal gearbox, 4
>     speed' section showing the mainshaft assembly as 'plate, spring
>     bearing' and 'plate, bearing,' but only for the pre-BJ8 cars on
>     the front of the gearbox (by the first motion shaft). So, did I
>     miss something, as I don't recall ever seeing them in the OD
>     adapter in 2 rebuilds (the catalog doesn't show them)?
>
>     For the BJ8, the catalog shows 2 available shim sizes, in lieu of
>     the bellville washer and 'plate,' I presume, but I installed DWM's
>     'uprated' shim and had to have the bellhousing machined appropriately.
>
>     https://www.bighealey.co.uk/index.php?route=product/product_grouped&product_id=34295
>     <https://www.bighealey.co.uk/index.php?route=product/product_grouped&product_id=34295>
>
>     Bob
>
>     On 8/27/2025 1:30 PM, Michael Salter wrote:
>>     Those "rings" are the Bellville washer and shim that go into the
>>     adaptor plate to eliminate end float of the mainshaft bearing.
>>
>>
>>
>>
>>     ------------------------------------------------------------------------
>>     *From:* Healeys <healeys-bounces at autox.team.net>
>>     <mailto:healeys-bounces at autox.team.net> on behalf of Leonard
>>     Berkowitz via Healeys <healeys at autox.team.net>
>>     <mailto:healeys at autox.team.net>
>>     *Sent:* Wednesday, August 27, 2025 3:50:01 PM
>>     *To:* healeys at autox.team.net <healeys at autox.team.net>
>>     <mailto:healeys at autox.team.net>
>>     *Subject:* [Healeys] Advice and guidance needed for OD
>>     reinstallation
>>     Hi. All
>>     I finally figured out how to get the OD out of my BJ7. Now for
>>     getting the new one installed. I found two rings sitting on the
>>     output shaft which I believe are fitted to the adapter plate.
>>     (See pics attached). The problem is going to be how to keep them
>>     in place while maneuvering the new OD into place. I was thinking
>>     of using either white lithium grease or wheel bearing grease.
>>     Any suggestions?
>>     Thank you in advance for any help you can offer.
>>
>>     Len Berkowitz
>
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