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Thread: Series 2A gearbox rebuild

  1. #1
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    Series 2A gearbox rebuild

    A lesson learnt this past fortnight, i dismantled what i believed to be a Series 2A gearbox from a vehicle i am trying to refurbish as a daily driver. I had removed a Series 3 gearbox from a vehicle i had acquired in the past and had intended to use in my Series 2A as it had synchronous clutches for first and second gears which would assist the wife to drive it heaven forbid she was ever allowed to. I dismantled the gearbox (Series 3) to inspect the internals and found first and second synchro damaged. I then dismantled the original gearbox from the vehicle and found the last person hadn't been as studious as i would have liked. Both the input shaft and the output shaft locking nuts were loose destroying both shafts, i fully dismantled the gearbox and assessed my options. I couldn't rebuild either gearbox from what i had so after going through all scenarios i called Gromit, he was able to help me out with an early Series 2 box that was in good condition, i picked up the box and brought it home to dismantle it and check what parts i would need to make a good gearbox for the vehicle. Now this is where things get interesting, i thought to myself i will put all the good parts in the Series 3 housing as its the newest and best including the bigger lay-shaft bearing. So i started reassembly checking backlash and tolerances all seemed within manufacturers specifications. So i fully assembled the gearbox only to find the reverse gear would not engage correctly, i dismantled the gearbox and inspected the reverse gears, i had swapped the lay-shaft from the Series 3 to allow the larger bearing bell housing to be used but with the original reverse gears there was no clearance between the idler gear and the lay-shaft to allow reverse to be selected. I then swapped all the internal parts to the Series 2 gearbox housing and installed the original Series 2A bell housing which allowed all the components to operate as designed.
    Now my problems i thought were over but little did i know the bell housing that came from my vehicle and matched my particular clutch throw out system was from a military vehicle and it had an extra seal designed to prevent water ingress into the gearbox so it had a different input shaft to what i had obtained from Gromit. So to move forward i had to make a decision purchase a special input shaft to suit the clutch throw out bearing configuration or remove the seal from inside the clutch housing and rely on the original design of a reverse thread to prevent oil from escaping into the clutch housing possibly rendering the clutch inoperable. I decided to go with the original design remove the seal and see how i go. I know this is long winded but i thought i should try to let people know yes the gearboxes are supposed to be similar but there are lots of variations to be aware of, i chose to mate the finished product with the Series3 transfer case as the internal bearings and shafts are so much bigger and robust than the earlier designs you would be silly to choose the earlier version if you had the choice. Now before all the rivet counters jump on me this vehicle is to be my daily driver till i cannot drive any more and i mean from here on in i am over computer operated vehicles. I am not old just 68 but plan on doing a lot of outback journeys and fishing trips in this vehicle, i can carry spare plugs, point, condensers, starter motors, alternators etc and fix them roadside i cant fix a computer. So my choice i hope to have the vehicle on the road later this year it is a Series2A tray back i am keeping as original as possible but with enough equipment to make for comfortable journeys in my senior years.

    Gippy
    I have included some photos to show what i came up against from the different reverse gears to shaft sizes and seal position.


    Series 2 and Series 2A reverse gearsa on layshaft..JPGIMG_2076(1) Series 3 and Series 2A transfer case idler shafts differences..jpgIMG_2050Clutch trow out housing Series 2A.JPGIMG_2052 Clutch shaft Series 2A.JPGIMG_2053Clutch throw out bearing with internal water seal.JPGSeries 2A bell housing with large layshaft bearing.jpgSeries 2 and Series 3 layshaft showing bearing size difference.JPG

  2. #2
    JDNSW's Avatar
    JDNSW is offline RoverLord Silver Subscriber
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    Perhaps worth pointing out that this gearbox was built and installed in a number of different vehicles over a period of more than fifty years from 1932. During this period there were a myriad of changes made, and the only really effective way of finding out is to pull it to bits and have a look.
    John

    JDNSW
    1986 110 County 3.9 diesel
    1970 2a 109 2.25 petrol

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