Front Cover Removal in situ

[frodo]

'95 Jap 1275 Automatic SPI A/C

I have removed all the bolts, the cover is loose.

When trying to lift up the front cover, the inhibiter hit the subframe. If I try to remove from the bottom, the casting for the oil filter hits the subframe.
Any tips to get the cover free?

Thanks.
Jon

[jockduck]

Hi, I know the cover on early cars can be removed in situ, but they don't have the inhibitor switch on the cover, if you can't remove the inhibitor its certainly more difficult, any chance of un bolting the engine mounts, exhaust, drive shafts and moving the engine backwards?
Jock.

[frodo]

Hi, Jock!

Thanks for the tip.

I can't see the motor mount bolts on the torque convertor side with all the SPI and brake booster equip in the way. But, you did get me thinking that maybe if I detached the top and bottom engine steadies and loosen the exhaust hangers, I may be able to rock the motor enough to sneak the cover thru. All I need is about 1/2" more clearance.

One of my more destructive thoughts was putting a cutting wheel on my angle grinder and cutting a 1/2" off the lip of the front subframe. There is a small indent there already, which was probably used to drop the complete motor/tranny assembly in from the top at the factory. I could weld it back on afterwards to restore the strength.

Hmm.....

Jon

[kiwimini]

Not a simple job.. I removed the oil filter housing from the cover - 2 bolts, and you will need a new gasket ; then removed the entire inhibitor unit.  Released the top engine steady mount at the engine end. This allows extra 'swing' movement to remove the cover.  Good luck, and buy more bandaids. 

[frodo]

Kiwi,

Did as you suggested, but also had to remove the bottom steady. Put a floor jack with a 2x4 piece of lumber under the rear of the gearbox and lifted up slightly.

I had to remove the grill opening support bracket as the A/C compressor and hoses were in the way. COVER OUT! All to fix a leaking gasket.

I was surprised how shiny and new everything looked inside.

Jon

[jockduck]

Hi again, a leaking gasket, did you consider a dab of silicone sealant externally ? I know its a bodge but to save disturbing a lot of stuff and your secret would have been safe with us.
Jock

[frodo]

Hi Jock,
That would seem like a quick way to sort it.  

Here is the back story....I purchased the car off of eBay after the seller had re-listed the Mini several times. It was 2,000 miles away and I could not do a personal pre-buy inspection. The seller sent me many pictures and the story about how his daughter was driving the car when the left front wheel decided to part the car. There was brake rotor, dust shield, wheel flare and wheel damage as well as broken wheel lugs. Other than that, it seemed in pretty good shape. Having owned 7 classic Minis, turning a wrench was not a problem. This was to be my first auto gearbox Mini, a gift to my wife who is "shifting" impaired. We negotiated a reduced price and I had a transport company pick it up.

All my classics leaked at some point, but this one was like the Exxon Valdes! Hee Hee!!

When I received the car, the gearbox had so much black silicone on it that it was hard to see any aluminum. I spent hours removing it. I HATE SILICONE!!!! The filter canister had 2 large o-rings which caused it to leak and created quite a mess. I replaced the control rod seal which was leaking badly, but still had a leak from the front cover. I have learned from past experience, that for me, it is better to get to the root of the issue and fix it, rather than patch and have to go back and do the correct repair. I will try to post photos later. Thanks to everyone that posted their ideas.

Jon

[jockduck]

Sounds like a good story, I also have a wife who has lost the ability to efficiently change gears on a manual so its autos only in the fleet now. I also have a bit of love/hate thing with silicone, it is brilliant in the right places but I have found it in all the wrong places too, My auto Mini leaks oil too, I start from the top as regards oil leaks and work down, my engine leaks somewhere around the sump/gearbox half moon seal but I can't nail the leak point exactly so I put up with it until something more serious drives me to pull the engine.
Jock

[kiwimini]

Pleased you got the cover off. I had previously removed the A/C compressor and pipes as contemplating a complete change to manual box & engine. Also gave me access to #1 plug as I remounted the alternator to the usual position.