The next major component to be overhauled was the gearbox, this also originally came from a mk2 escort and this particular one is from the 1600 sport model which featured closer ratios than standard. The gearbox was purchased through eBay and collected from near Meadow hall. The first job once it had been picked up was to thoroughly clean it up and check for any damage.
The original plan then was to replace the oil seals & gaskets whilst checking over the gears and synchros as much as possible from the top of the box without removing them. This was duly started but whilst replacing the tail shaft gasket one of the clips in the gear hub slipped out of line meaning the main gear cluster would need to be removed completely to reassemble it.
This was a fairly major job but would mean we would gain a more in-depth understanding of the workings of the gearbox and meant we could check over the rest of it more thoroughly.
The job was started by rotating the tail shaft and then removing the lay shaft which would allow the second gear cluster to be lowered down into the bottom of the box and hence allow removal off the main cluster and input shaft. These components could now be checked over properly and it was then found that two of the synchro rings where worn out and would need replacing before the gearbox could be rebuilt.
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