gearbox rebuild kit? Has anyone seen them?

[4X4byV8]

hi im new on here... i have used the search but had no luck with finding what i wanted. Basically im going to do an overhauld job of a series 2 box, ive heard of rebuild kits for these but wanted to know what you guys recommend? where and what to buy etc?

Im not sure on the reason for the box failing but its probably somthing to do with having a v8 bolted to it.

Its never been happy going into second gear, despite the fact its meant to be synchro meshed in all gears but first. It now won't go in second at all, the transmission will also lock up if the vehicle rolls in gear with the clutch down. Also it will (only now and again) try and stall the engine when releasing the clutch in neutral. Despite all this it will still drive and move along happily.

Ive drained the oils and had no bits come out with it... hopfully thats not because any pieces are bigger than the drain plug

If anyone has a clue what the symptoms mean i would be greatful to hear what you think. Box should be out in the next week or so anyway...

[mickeyw]

This sounds possibly like a clutch related problem to me. Have you checked the fluid level in the clutch reservoir?

Does the gearstick feel like it is actually engaging/disenghaging gears when you move it around?

Hopefully a grown up will be along with some better advice shortly, but I would check the easy things before you go ripping the garbox out/apart.

[FridgeFreezer]

By all accounts not a hard job to rebuild one, all the parts should be cheap & available from Paddocks et al (I vote Brit-car.co.uk).

These days it's worth taking a good look at putting an LT77 or R380 in, they were designed to cope with the V8 and are more civilised. Have a read back in this forum, it's been covered plenty of time.

[4X4byV8]

thanks for responding. if its not too bad a job ill get the box out either way, id have to if ive lost second. all the other gears select fine as they did before, second gear will only just reach the edge of the teeth but no go in... could it possibly be a dislodged synchro spring? I wouldnt have thought its the clutch, but that is on my list of things to replace anyway as its still standard 9"

[tuko]

In Bearmach's 2010 parts catalog they list a series 2a suff A on gearbox bearing kit as BK 005B.

Mailorder4x4 deal with only with Bearmach so you know your getting quality.

Cheers,

Todd.

[secondjeremy]

The Series 2/2A gearbox has NO synchromesh on 2nd or 1st gear. Series 3 boxes have full synchromesh.

If you want to overhaul it the best thing to do is to take it to bits, examine the components and replace whatever is necessary as well as the 3 flat springs in the 3rd/4th synchro unit (they fall out and jam the synchroniser, get in the oil and damage the gear teeth and so on.)

You'll probably find that you can obtain good quality bearings (if needed) from specialist bearing suppliers (take your old one in)

You need to get the official workshop manual - it'll tell you how to get it to pieces.

Have you had a look at the end of the gearstick? Its possible that the end has worn and is slack in the end of the selectors. This may mean that sometimes the selectors don't return to the centre properly and will not allow the gear to be selected.

[Les Henson]

I can't see how anyone can supply a gearbox rebuilt kit, other than bearings, gaskets, seals, thust washers, shims, etc. A gearbox fault is generally unkown (even if it has a known common fault), so the rebuild kit would most likely not be adequate to do an effective repair without having to buy something else. I would take it apart, see what the problem is, then buy whatever you need to do the repair.

Les.

[wombat1971]

rebuilt my box recently got all parts from mailorder4x4 some took a few days to come in but they were the most helpful of all i spoke to. replaced all clusters bearing gaskets seals etc and had change from a few hundred bargain in my book have bought recon boses before noisy & ruff very quickly coz only the really bad bits had been replaced not worth the money in my book NEVER again ,

[4X4byV8]

thanks for everyones input. ive managed to find the fault, when i had the top cover off i noticed the 2nd gear stop bolt had been incorrectly set, the selector fork wasn't engaging the gear completely on the shaft. it had only been running on half the teeth, thats bad enough with the standard engine but im suprised its lasted me this long with the v8 in there. I could have just adjusted the stop to run on what was left of the teeth but that would be a complete bodge so ive now got the box out. im very suprised with the condition of the rest of it, it all appears to have no other wear or damage but i cant seem to explain how it kept locking up, i hope that'l sort itself out once its rebuilt. Got a 9.5" taxi clutch to go in there too

[4X4byV8]

hi everyone, thanks for the replies i got.

I had the box out, on the bench and split open. Its now ready to go back in once ive got the last coat of paint on the steelwork. I came across a few problems with the gearbox that I thought would have been quite major, but it had still been working up until I removed it... trusty landrover!!

A few of the problems were-

rear nut on the mainshaft (in the transfer box) had unscrewed completely back to the point it wore the rear bearing housing out, this was the main issue as all gears on the mainshaft, when in neutral were still engaging.

second gear drive dog was chewed off where first gear cog comes on to engage.. hence the jumping out of second.

The first gear on the layshaft had its days, ive been told its common to see them like this as its also what takes the pain when you hear that CRUNCH going into reverse.

mainshaft distance sleeve had broken up, ive replaced it with a new type as the manual says to.

here it is compared to an original complete one-

The mainshaft pegs were broken off because of the mainshaft distance sleeve spinning. They ended up flush in the shaft so I replaced the holes with our spark eroder.

You may just be able to make them out-

I still couldn't believe the landrover drove along without more problems than second gear.

[Duncan]

Thats really Amazing she still drove so well, Solihull magic!

[sotal]

Wow that was quite bad, makes me think mine looked like brand new now!