2.5N/A to 200tdi conversion

Freelaner · Nov 17, 2011

Is that the only mod you need to do to use the disco transfer box?

landrover11019 · Nov 17, 2011

Good idea spreading the chassis to get the cross member out.

GRATCH · Nov 18, 2011

Hoyt-Protec said:
Is that the only mod you need to do to use the disco transfer box?

As far as I know. I'll report if I find anything else that needs doing.

GRATCH · Nov 28, 2011

Done a bit more today, but forgot about takin lots of piccies.:doh:

Disco transfer box on to 90 gearbox.

New crank seal, clutch on disco engine. 1 stud and two dowels removed from flywheel housing to allow 90 bellhousing to mate.

Then I manhandled the gearbox over to the engine ready to get the engine crane to help to mate them and thought I'll just give it a quick try by hand, this was the result

also put exhaust downpipe on whilst got good access.

landowner · Nov 28, 2011

You realise that GKN pallet will have to go back

Nice one, you'll have yours done before mine at this rate.
Are you uprating the brakes? I'm putting late 110 CSW calipers on the front.
I've got Disco front springs and heavy duty rears for towing, worked a treat on the 110 but not sure how they'll be on the 90.

GRATCH · Nov 28, 2011

The pallet will go back sometime, they int missed it for bout 8 months though

I gotta get it mobile at least, as soon as poss as the cows will need coming in soon.
I reckon I'll leave the brakes standard, just overhaul them, for now and I may put the standard springs off the donor disco on and see how it is.

landowner · Nov 28, 2011

GRATCH said:
The pallet will go back sometime, they int missed it for bout 8 months though
I gotta get it mobile at least, as soon as poss as the cows will need coming in soon.
I reckon I'll leave the brakes standard, just overhaul them, for now and I may put the standard springs off the donor disco on and see how it is.

Disco springs are ok I found but then I like a soft ride. Weren't too bad with weight on the trailer either.
the Disco coped with another Disco on the trailer from Cornwall up to here at 55 mph and level as can be so 90 should be ok

GRATCH · Nov 29, 2011

Some more done today.

Made a few new brake pipes whilst there's easy access.

Re-filled gearbox and trannybox whilst there's easy access.

Then out with the engine crane and in with the engine.

I've decided to use the donor disco engine mounts so i ground off the old chassis mounts and the new ones will need welding on when I'm happy with the position.

Gearbox mounts bolted on to start alignment.

Engine in place sitting on a trolley jack for now.

Station House · Nov 30, 2011

Loving the piccys Gratch

TheKeymeister · Nov 30, 2011

Nice work, I feel alot better now, mine was sat on a jack and a concrete block just like in your pic for about a week while I got some stuff together, was slightly worried about it but now someone else has done it...

My mate is mid way through this conversion himself, dunno if he's seen the thread, he's doing it without the turbo for now as too tight to sort out the rad/intercooler/exhaust for now, and he does eventually want to do the disco transfer box....

GRATCH · Dec 6, 2011

Finally managed to snatch a coupla hours on the landy after having to replace axle u bolts and strip and adjust handbrake on a mates merc sprinter yesterday and having to chase a coupa bulls back in their pen today before I started.

So I glued on the engine mounts with a bit of burd**** and patched where the inner wing bracket attatches to the footwell.

craigyb · Dec 6, 2011

im doing my conversion will be following this thread to see how you get on. also what are the benefits of putting the disco tranny box on?

Karlos28 · Dec 6, 2011

class thread.. i am wondering wether to take the whole lot out again to get my box reconditioned and swap transfer box, or if i should just try and get the gearbox off.. leaving the engine in.

i have noticed recently.. that the left hand engine mount rubber damper bit.. is quite severely stretched forwards.... i think i will have to look into it pretty soon.. it cant be good!

GRATCH · Dec 6, 2011

A few other people have done 200tdi conversions on here, a lot betterer than my thread will be inorl and theirs are finished.

Karlos28 · Dec 6, 2011

yeh i used theirs quite a bit. it a really easy job i thought tho..

GRATCH · Dec 8, 2011

Right, I've come across what maybe a problem.......the clutch slave cylinder rod seems to be too far back in the bell housing so the slave cylinder won't actually push it to release the clutch, almost like I've not put the release bearing in, which I did as I was suprised that the plastic staple that holds it to the clutch fork was still there. Anyone got any ideas if I've missed something before I pull the fookin engine and box out?

landowner · Dec 8, 2011

GRATCH said:
Right, I've come across what maybe a problem.......the clutch slave cylinder rod seems to be too far back in the bell housing so the slave cylinder won't actually push it to release the clutch, almost like I've not put the release bearing in, which I did as I was suprised that the plastic staple that holds it to the clutch fork was still there. Anyone got any ideas if I've missed something before I pull the fookin engine and box out?

My cluch pushrod has a spacer which fits on the inside . must be to lengthen the rod. The push rod butts up to it and it locates inside.

Maybe some rods are different, mines off a 300 I think.

GRATCH · Dec 8, 2011

Hmmm. Don't think that's the answer as it seems to be right back in the bell housing. This is where I'd expect it to be....

......but I can push it in level with the bell housing and pull it back out to more than the piccie.
I'm gonna have to take it apart and check before I get too much further putting it back together:doh::doh::doh:

jamesmartin · Dec 8, 2011

landowner said:
My cluch pushrod has a spacer which fits on the inside . must be to lengthen the rod. The push rod butts up to it and it locates inside.

Maybe some rods are different, mines off a 300 I think.

300 tdi rods are look the same just a little longer

jamesmartin · Dec 8, 2011

GRATCH said:
Hmmm. Don't think that's the answer as it seems to be right back in the bell housing. This is where I'd expect it to be....

......but I can push it in level with the bell housing and pull it back out to more than the piccie.
I'm gonna have to take it apart and check before I get too much further putting it back together:doh::doh::doh:

maybe not quite so far out but 20mm ,is fork on pivot correctly ,clutch plate

2.5N/A to 200tdi conversion

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