Manual Gearbox Identification
There are two manual gearboxes fitted to the SD1 range - a 4-speed and a 5-speed. We have concentrated here on the 5-speed version because of the rarity of 4-speed models. However, as the 4-speed is essentially a 5-speed with fewer internals, it would be a simple matter to fit a 5-speed 'box in place of a 4-speed. There were a number of changes affecting gearbox internals over the years and many parts are not interchangeable. Therefore, it is important to identify your gearbox by the number stamped on the left hand side - the vital figure being the suffix A, B, C or D.

5-Speed Gearbox;
Reconditioned.
All models (except 2000 & 2400TD) - (1) - UKC9076RHD
Heavy duty - also suitable for performance engines.
2000 & 2400TD - (1) - UKC9076R
Suitable for 3.9:1 ratio axle.

Gearbox Oil
Early 4 & 5 speed models used SAE75W oil. From approximately 1980 onwards, Rover used automatic gearbox oil (ATF) in the manual gearbox, to help improve gear selection from cold. Our reconditioned 5-speed gearboxes use ATF.
The oil capacity is 1.5 litres.

Unipart ATF (0.5 litre) - (ar) - GGL175

Gearbox Mountings

Gearbox mounting rubber - (2) - CRC454A
Except 2400TD.
Gearbox mounting (2400TD) - (1) - TKC2642
Setscrew (for above) - (4) - SH108201
Centre buffer (rear mounting bracket) - (1) - CRC581A
Except 2400TD.
Bolt - (1) - BH112121
Thin nut - (1) - NH112041
Washer - (1) - WC112081
Setscrew - (4) - SH108201

Clutch Housing/Operation

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5 Speed Manual

Bellhousing;
3500 models - (1) - FRC133
2600/2300 - (1) - RKC660R
2000 - (1) - PKC1576
2400TD - (1) - PKC1767

Bellhousing bolt kit - (1) - RB7130
V8 models.

Dirt Shield - lower bellhousing;
3500 models - (1) - FRC142
2600/2300 - (1) - TKC869

Clutch operating lever - (1) - LBU1234
All models.
Slipper pads - (2) - 159003A
All models.
Clip (push rod retaining) - (1) - UKC1806

Release bearing & sleeve assembly;
3500 -
To 1985 (non self-centering) - (1) - FRC5368A
1985 on (self-centering) - (1) - GRB90247
2600/2300, 200 & 2400TD -
To 1985 - (1) - FRC5369A
1985 on - (1) - GRB90246

Release bearing only;
Non self-centering - all models - (1) - GRB209
Note: Later, self-centering release bearings can be fitted to earlier models
only as a complete assembly, including self-centering type clutch cover.

Speedo Cable & Transducer

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Speedo cable;
RHD models
1976 - 1980 (release arm connector) - (1) - GSD295
1980 - 1982 (eurosnap connector) - (1) - GSD380

Speedo drive gear;
1976 - 1982. Models with mechanical speedo.
3500 (20 teeth, orange) - (1) - 219001
3.08:1 axle ratio.
2600/2300 (23 teeth, black) - (1) - 219004
3.45:1 axle ratio.

'O' ring (drive gear housing) - (1) - TRS1620

Speedo transducer;
1982 onwards (electronic speedo).
2 pin connector -
3500 (20 teeth, orange) - (1) - DRC8007A
3.08:1 axle ratio.
2600/2300 (23 teeth, black) - (1) - DRC8015
3.45:1 axle ratio.
2000/2400TD (22 teeth, red) - (1) - DRC8016A
3.09:1 axle ratio.
Total terminal security connector -
3500 (20 teeth, orange) - (1) - DRC8172
3.08:1 axle ratio.
2600/2300 (23 teeth, black) - (1) - DRC8174
3.45:1 axle ratio.
2000/2400TD (22 teeth, red) - (1) - DRC8173
3.09:1 axle ratio.

'O' ring (for transducer) - (1) - 13H2792
Retaining bolt (transducer) - (1) - SH106251

Casing & Components

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5 Speed Gearbox Rebuilds
The 5 speed gearbox requires specialist tools and knowledge to dismantle and rebuild, and is normally beyond the ability of the DIY enthusiast. We therefore recommend the fitting of an exchange gearbox unit. However, we do stock a full range of components should you wish to rebuild your own 'box. Listed below is a selection of parts most commonly needed.

Main Gearcase;
Suffix A & B - (1) - ULC2045
Suffix D - (1) - FRC8084

Oil drain plug;
Suffix A, B & C - (1) - UKC3771
Suffix D - (1) - FRC6145A

Fibre washer;
Suffix A, B & C - (1) - WF513
Suffix D - (1) - FRC6084A

Rear extension case & oil pump - (1) - TKC1320
Suffix A, B & C.
Oil pump gears & shaft - (1) - RTC2057A
Oil filler plug - (1) - UKC26
Fibre washer - (1) - WF513
Selector shaft 'O' ring - (1) - UKC7

Front cover assembly;
Suffix A, B & C - (1) - ULC1283
Suffix D - (1) - FRC6019

Gaskets & Oil Seals

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Front oil seal - (1) - UKC1060
All models.

Rear oil seal;
Suffix A, B & C - (1) - UKC3949
Suffix D - (1) - FRC6084A

Gasket (front cover) - (1) - ULC1284

Gasket;
Gearcase to centre plate - (1) - TKC1229
Centre plate to housing - (1) - TKC1235

Gasket - extension case to centre plate - (1) - TKC1235

Input Shaft & Mainshaft

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Input shaft;
Suffix A & B - (1) - TKC3533
Suffix C - (1) - RKC4168
Suffix D (except Vitesse) - (1) - RKC5485
Suffix D (Vitesse) - (1) - FRC6094L

Bearing (front of input shaft);
Suffix A, B & C - (1) - ULC2445
Suffix D - (1) - FRC7145A

Bearing (rear of input shaft) - (1) - GHB107
All models.

Mainshaft;
Suffix A (to 1982) - (1) - TKC3111
Suffix C (1982 onwards) - (1) - FRC5350
Suffix D - (1) - FRC5961A

Synchro rings - (5) - FRC8232
All models.

Mainshaft taper roller bearing;
Suffix A, B & C - (1) - UKC169
Suffix D - (1) - 0494369

Speedo drive gear;
3500, 2600 & 2300 (black) - (1) - TKC1274
2000 & 2400TD (white) - (1) - TKC1273

Rear mainshaft bearing;
Suffix A, B & C - (1) - 533360A
Suffix D - (1) - ULC4046L

Layshaft

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Layshaft gear cluster;
Suffix A, B & C - (1) - FRC7213
Up to 0162429C.
Nut (for above laygear) - (1) - FRC7214
Suffix D (except Vitesse) - (1) - FRC6647
Up to 53889D.
Suffix D (Vitesse) - (1) - FRC6648
Up to 53889D
Suffix D (Vitesse) - (1) - FRC7213
53890D onwards.

Layshaft bearing - (2) - ULC1796
All models.

5 Speed Gearbox Internals

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1st Gear (suffix A, B & C) - (1) - TKC735
2nd Gear (suffix A, B & C) - (1) - TKC267
3rd Gear (suffix A, B & C) - (1) - TKC268

3rd Gear (suffix D);
All models (exc Vitesse) - (1) - TKC6962
Vitesse only - (1) - FRC5885

5th Gear (suffix A & B) - (1) - TKC5317
5th Gear (suffix D) - (1) - FRC5162A
Selector Fork 1st/2nd (suffix D) - (1) - FRC8124
Selector Fork and Bracket - 5th gear - (1) - RTC2058A
All units.
Synchro Hub - 3rd/4th (less rings) - (1) - UKC5843
Reverse Idler (suffix A & B) - (1) - UKC1644

Bush 1st speed (suffix A, B & C);
40.18/40.23 - (1) - TKC1478
40.28/40.33 - (1) - TKC1480

Bush 1st speed (suffix D);
40.21/40.26 - (1) - FRC5244
40.31/40.36 - (1) - FRC5246A
40.36/40.41 - (1) - FRC5247

Gearchange Housing

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Gearchange housing assembly - (1) - TKC3821
All models.

Mounting bush;
Gearchange housing to gearbox.
Plastic (original) - (8) - UKC854
Polyurethane (longer lasting) - (8) - UKC854POLY

Gear lever;
All models to 1982 - (1) - TKC4300
All models 1982 on - (1) - FRC7746

Gear lever retaining cap - (1) - UKC3159
Anti-rattle plunger - (1) - 22G1988
Plunger spring - (1) - 22G1989
Gear lever knob - (1) - DAM6658
All models 1982 onwards.
Gear lever grommet (black vinyl) - (1) - JRC1679
1982 onwards.
Gear lever grommet - (1) - BRC354
Fits transmission tunnel.
Reverse light switch - (1) - TKC6761
Locknut (for reverse light switch) - (1) - 22A1613



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Sat, 11 Oct 2008