D2 Lost 2nd gear

Hello all,

Just lost 2nd gear on my 2003 Disco. Stripped down all the lever assembly as far as and including the selector housing. The lever and selector look in perfect shape - only done ~55k miles.
Any suggestions as to the cause/fault.

What about the plastic Bush at the bottom of the gear lever (in the selector rod).
That's often the cause when it wears away or breaks up.

in what way is 2nd lost,

All gear lever related parts look in A1 condition. I’ve disassembled as far as the selector housing and rammed the selector rod as far as it will go, then started engine with clutch in. Upon releasing clutch 2nd does not engage at all. All other gears engage Ok

Added a couple of images with the selector in 2nd gear. 1st image shows state with no transmission. Second image I use a screw driver to push selector shaft as far as it will go after which there is a grind from the box

jamesmartin said:

in what way is 2nd lost,

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Yeah, is it just impossible to select or does it go in sometimes?
Was there any symptom prior to the issue like noise or something?

This is interesting because the usual 2 issues - bias spring and plate would appear to be irrelevant and from the look of the selector bushing in your photo that too is fine (spring clip in place as well).
If you are selecting 2nd then the single selection shaft is moving fully forward and I'm guessing you say it does so easily on other gears so its not a selector fork to rod issue.

Thanks,
I had used the car with no issue on Friday morning. Then used an hour later, pulled out of driveway, shifted from 1st to 2nd then sounded like it immediately jumped out of gear. I could not get 2nd at all afterwards. If you look at the difference between pic 1&2 there is approx 1.5mm between selector yoke and stop. Pic 2 is where I have forced selector shaft to take up that 1.5mm. You can hear a synchro grind or similar when forced as far as selector shaft will go.
Thinking the worse now and a gearbox swap out

2nd gear baulk ring is usually the first to go along with 3rd

Thanks. Would a worn baulk ring stop me engaging 2nd completely though? I would have expected to have difficulty engaging if the ring was worn, but eventually engaged. In my case 2nd will not engage at all...

if lever wont push back enough it could be a broken synchro spring,but going on what youve said box needs to come out

jamesmartin said:

if lever wont push back enough it could be a broken synchro spring,but going on what youve said box needs to come out

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Thanks @jamesmartin
It’s acting like I am in neutral.
I take it a box swapout is the most sensible option then. I don’t have the experience or facilities to dismantle a gearbox.

rosedale73 said:

Thanks @jamesmartin
It’s acting like I am in neutral.
I take it a box swapout is the most sensible option then. I don’t have the experience or facilities to dismantle a gearbox.

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Recon exchange from Ashcrofts is what you wants.

A guy at work dropped a fooked one at the yard for me as he bought it in good faith on eBay and it turns out it is actually worse than the one he took out

Luckily he did the swap himself but it could have been really expensive, it should be delivered in the yard on Thursday and the sh!tter picked up as the exchange core unit.

rosedale73 said:

Thanks @jamesmartin
It’s acting like I am in neutral.
I take it a box swapout is the most sensible option then. I don’t have the experience or facilities to dismantle a gearbox.

Click to expand...

I'd suggest rebuilding the gearbox - IF it has only done #55K, then the rest of it might be in nice condition, and worth rebuilding. I'd be hoping that you've just been unlucky with whatever the failure turns out to be....

I'd be considering service history of the box and state of the oil etc in making any decision