200tdi into hybrid series / disco, with pics!

bit of a back story, got a transit 2.5di mounted to a series box on a disco chassis, gearbox blew so I decided to replace with a lt77 from a fender and 200tdi from a disco. (New photos on page 5)

job list

Move gear box - done
grind down old engine mounts - done
sort raditor and intercooler mounts - done
fit engine mounts - nearly done
move fuel filter
remake gear lever to clear bulk head - done
fit air box
fit exhaust
fit axel breathers
speedo cable
fit new clutch, flywheel and flywheel housing
Move brake pipe junction done
bleed power steering
bleed clutch
sort glow plug relay / wiring
change 200tdi oil + filter
fit seatbox
fit battery
fit handbrake
get rid of unnecessary wiring done


got a new lt77 to replace the series gearbox that was in. it was a series suffix D, gearbox blew up, and the ford transit engine was a pile of crap, so I decided to convert to the 200tdi.



transit lump in there. notice how far the engine is sitting back.



transit engine out, for sale has the adapter plate to fit onto series box, easy conversion...



engine bay , needs wiring sorting and painting. New mounts will be added one gearbox is in.



getting ready to pull out disco engine.



out, needs cleaning, covered in 200,000 miles of crud and oil leak coming from rocker cover.



bit of paint. disco power steering box in. replaced the old one with ths from the disco as the steering on that was very good. Also used the track rod from the disco as the tie rod hook up was different.



unbolted the disco transmission cross member and bolted onto chassis. seems a little flimsy on the disco gearbox mount / contraption. also seems to be sitting a little high.



cleaned her up a bit and replaced rocker cover gasket and half moons.

got off the flywheel housing to send off to glycone engineering, might have to put it back on so I can line up where to put to engine mounts, going to mount the engine onto the gearbox the tack the mounts in place.

Will get a photo up of the throttle linkage and the progress I make tomorrow.


throttle cable on. assuming the tension from the injector pump return spring will keep it in place.





rad and inter cooler on okay. using frame from disco





gearstick bent the other way, went really easily with heat from blow torch. Now clears the bulk head.




offside engine mount on

How short are your props looking ?

Rear prop from original vehicle fits just right, from from from disco fits just right.

gearbox has the short bell housing!

hmmm strange, last conversion I saw with a 200tdi and fender lt77 needed a tiny rear prop with wide angles!

Has your engine and box been moved forward a bit?

yeah engine will have to be moved forward little from old mounts, looks like it all measures up okay.

The chassis is a chopped disco chassis to 90 inch. the The prop shaft is about 18 inches, it only fits when fully compressed in though, so might have to shorten it a fraction.

ahh you've got two extra inches to play with than the other guy then and he didn't move his engine forward either!

I probably should have gone down the same route as you with the LT77 but too late now

Dr_evil said:

ahh you've got two extra inches to play with than the other guy then and he didn't move his engine forward either!

I probably should have gone down the same route as you with the LT77 but too late now

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Nah it's not

yeah , the only experience I have with series boxes is that they cant handle anything more than the 2.25.

Not sure if th box is even mounted in the right place but it seems about right, just a little high up. Ill drop the engine in and see how things line up

fergus123 said:

yeah , the only experience I have with series boxes is that they cant handle anything more than the 2.25.

Not sure if th box is even mounted in the right place but it seems about right, just a little high up. Ill drop the engine in and see how things line up

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The engines usually sit ruddy far forward near the radiator, I see this being an issue

200tdi ayre said:

Nah it's not

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The money has been spent and the box is welded in place same as the engine

Plus the jag axle is far more tempting

fergus123 said:

yeah , the only experience I have with series boxes is that they cant handle anything more than the 2.25.

Not sure if th box is even mounted in the right place but it seems about right, just a little high up. Ill drop the engine in and see how things line up

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The series box will handle the 3.5V8 and 200tdi just gotta be a bit more gentle with it thats all

200tdi ayre said:

The engines usually sit ruddy far forward near the radiator, I see this being an issue

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def lt77 isnt that much longer than a lt76 series box

jamesmartin said:

def lt77 isnt that much longer than a lt76 series box

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Aye but he's moving the engine forward already

LT230 is a lot longer than series box though isn't it ?

Will soon tell you how much abuse the series box will take.

Dr_evil said:

LT230 is a lot longer than series box though isn't it ?

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no ,a little but youve got the long bellhousing version

jai_landrover said:

Will soon tell you how much abuse the series box will take.

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My mates been through 4 series boxes in his 200tdi

Basically as we ALL told you way back when is you shoulda spent the extra and got a 90 gearbox!!!

200tdi ayre said:

My mates been through 4 series boxes in his 200tdi

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hes young i suppose ,and with a 40 year old box

200tdi ayre said:

My mates been through 4 series boxes in his 200tdi

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Different a TDI is very harsh always changing up and down the gears. A v8 can be very smooth and still driven hard if you get me. And as James says probably old ****ty boxes. IF I blow up 2 I will build one. My Bro has a genuine new 1 ton box under the workshop bench from when he was working at LR he got it as the buyer never turned up so brought it cheap. Still as new. But it will take more beers than I can afford to swing that!

Taking a trip up to Peterboro to a megasquirt open day for a jolly in a couple of weeks. I guess the 90 comper will be getting his 3.9 build and a megasquirt system after all. I knew he couldnt resist!

Yeah I use mine for towing and round the farm. Dont have time to be gentle haha.