Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Gearbox

Cover is now off. The inside is covered in sound proofing. This has foam like material stuck to the cover. The outside of this is silver with fibre strands running criscross. This material is stuck to the chassis vertical flange with white chewing gum like substance. What had happened is that the described material had torn along the top of the flange, but was still being held together by the fibre strands. Hence some upward movement but a hard stop when the fibres became taught.
Unfortunately the fault is in the gearbox, so engine out job as the bell housing is too big to come through the cockpit & then a gearbox re-build. This type of failure is not unknown on/in Ford transit gearboxes (same box) can either be the gate or selector forks.
I’ll post the outcome.

Ah bad news Bob.

I've never had problems engaging gears in my daily driver, 2002 4/4 with the MT77 box. Then at 25.8K ml/2009 the gate gradually disappeared. The service agent told me the box would not be damaged if I carried on driving. Over the next month I had no problem driving while the agent tried to get the Factory to fix it under some guarantee. Unsurprisingly the Factory were not interested and the agent sent the box to a specialist. The message that came back with the box was that a small part had worked loose and fallen out. Apparently, a well known problem in the world of gearboxes! 40K and counting with no further problems. (I just wish I hadn't written that).

Been a bit of a saga, long story of procrastination but another engineer has completed the repair.
Basically roll pin 17, had failed releasing ball 19. Hence the selector was unable to move around the gate 25. Also reverse pin 8 had broke, exactly when not sure but the indents on “bar” 5, were well worn. Funny reversing light was still working a couple of months ago.

Just engine & gearbox back in car & refit tunnel & trim. I might get car back next week. The car is my every day car so has been a right pain not having it.
But could have been a lot worse as with those bits floating about could have jammed into the gears & done much mischief.

Good to hear it’s sorted; a lot of work for a couple of roll pins!
Ideal opportunity now to grease prop shaft and front U/J before tunnel goes back on, or even to make access points in floor for future greasing access?

Good point Deejay. I’ve already sorted the factory access points for filler & electrics.