1800phil

Can anyone recommend a really good manual for a 2a, I’m currently in the middle of a gearbox rebuild and need some good exploded pictures of the main and lay shafts with all parts named. Also showing measurements and tolerances. Thanks in advance.

Cheers for post, most useful.

Cheers for replies, Decided to get a new head in the end as this seemed more cost effective in long run. All fitted and running like a dream.

I've been trying to strip the box down on my 2a. I've removed the overdrive with no problems and then started to try and remove the transfer box, I can see two bolts on the inside of the casing which obviously hold it to the main box, but how do I gain access to these? How do you take the gears out? Also I've remove clutch workings from inside the bell housing and undone the bell housing bolts, but the housing will only come forward about an inch, is it stuck or do you need a special tool to undo the large castle nut on main shaft? I've searched the net but can't seem to find this info on this, so any advise would be much appreciated.

Hi, I brought a Disco 1 some time ago as spares or repair with blown head gasket and extensive welding needed to get back on the road. I fitted a new head gasket like for like just so I could move it around the drive if needed, I have then spent many months welding, fitting new brakes etc the list goes on. The other day after fitting new water pump and P gasket the head went again!!! I've removed the head and its blowing in the same place between 2&3 so I thought about getting the head skimmed. After closer inspection I've noticed a crack (hair line) between the glow plug and injector which also extends to the valve seat on No 3 cylinder. My question is, will this be a problem or can I ignore it. Is the head worth skimming or should I look at buying new/second hand. Also the gasket I replaced at the start was the thickest with no holes stamped into it, does this mean the heads been skimmed before???? Not sure which direction to go next so any thoughts would be appreciated.

Hi, I've just brought a Disco 1 to put back on the road no history at all and its covered 160,000, first job is head gasket, blowing coolant out of exhaust. I've removed the head with no problems and inspected the gasket to find its blown between 2 and 3 cylinders. I've also noticed its got no holes to indicate thickness. After reading some other posts it seems the 3 hole is most common gasket! Should I just order a gasket with no holes and hope for the best? Or how easy is it to work out required thickness by measuring top of piston protruding the block. Any thoughts would be much appreciated.

Thanks for all replies, managed to get perfect match using code HCC.

Hi, I a series 2a which I think is finished in bronze green!!! I've been trying to get some paint mixed up but my local auto supplier wants a paint code!!! Can anyone advise me to where I might find the paint code on the vehicle or does anyone know the code for bronze green??

Thanks Eric, very useful.

Ok thanks for all replies. Even sat at idle when I try to engage 2nd it grinds. When I engage reverse you can feel spring in the gear lever and it will spring back into neutral if you let it go. All other gears the gate is floppy, is there any springs in side the selector gate which could of broken ?? If not I like the sound of series 3 box, plenty on ebay. Id like to get one I could recondition, one question though. There's some being advertised as series 2 2a 3 gear box, how can you tell if its a series 3 with synchros just from pictures?

I've tried double clutching again, but still getting grinding/dragging into gear. Is the fact I've a 200TDI in her making a difference, may be engine rev speed!!!

Ok cheers guys, thought I'd tried that but must need to improve my technique. Will give it another try in the week.

Hi, I own a 2a which is grinding into second gear. When cold at low revs it will change ok. Once warm and at higher revs it grinds when changing up and clonks when changing down, all other gears are fine. Before I start stripping parts off just wondered if any one had any advise or tips they could share.

Just fitted new gear lever housing to my 90 all working fine. I then put in a kill switch from power supply to ignition inside fuse box. I don't have any electrics lights etc when hand brake is off, all work fine when hand brake is on. I have taken kill switch out but problem is still there. Pulling hair out now, does any one have any ideas????

These pics might help if you think your having same problem. End of spring has worn a grove in both sides of the housing, making the spring stick and not sit on adjuster bolt.