90 to disco 300tdi and r380 convedsion

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chrisrawe

New Member
Posts
41
Hey all i started this project a out 2 weeks ago and after doing research there was alot of mixed thoughts arounds parts fitting and such like thats so, i took as many pics as possible to easily show people how easy it is..... So first of all find a pos disco!!

and get a mate to pick ur motor up and take where you have space

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Take stuff off disco and end up cuttjng the front end off as you cant un bolt it as easily as you thought :)

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take everything you can off of the car and leave as much as you can on the engine and gearbox!!

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After this stage feel good about nackering ur mate out and crack open some beers .....

Next you need to scrap the pos disco!!
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I had my old gearbox 3.9 block and tranny in the back of the disco so it was really back end heavy!!

next you grind off the old engine mounts... Mind were standard td mounts as i had a milner conversion kit for the v8...
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next...... Slide the gearbox engine and tranny as one unit and bolt tranny onto gear box mounts...... You need to take the disco ones off and fit ur defender ones........ Straight swap!!,

Then fit the engine mounts and brakets to the engine and lower to correct hight and tack weld in place...
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the next bits arnt really in order but are still relevent.... The rear of the tranny box on the disco is different so needs to be changed

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so you take the drum off undo the 4 bolts and take the shoes assembly off..... Dont take the big centre nut off as you dont need too.... And then undo the rest of the bolts holding the rear... thing off :) i put the 2 next to each other so you can see the differances..... The only differance is the defender one is mechanical and the disco one is electronic
 
clean up the defender one and use **** loads of sealant.... Attach the defender handbrake assebly etc and drum and rear prop
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after we tacked the engine mounts on i took the engine out to weld the mounts up properly and also changed tbe rear main oil seal, clutch, hd folrk etc
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after that was done i started connecting stuff up.... i already had a disco steering box and defender drop arm etc so i used the disco pas reservoir and pipes and they fitted perfectly!!

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now for the cross member... It has nothing to do with hitting the r380 gearbox!! It is purely for the exhaust, and since i brought a new 300 tdi defender exhaust i had to hack it about....

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i welded a 5mm plate over the top to try and give it as much strength as possible, however you can see from the pics that i had to cut the webbing away as well... But all in all i thought it fitted very nicely under the exhaust!
 
i fitted the fuel filter housing in the original td /200tdi location..... Now i dont know if a standard set of 200 pipes will fit straight in or if you need to lenghthen them, but to save hastle and since i didnt have an diesel lines coz it was a v8 i just brought 3 metres or 6mm id fuel line which fitted lovely

Oh and might i add that while taking pics i dropped my iphone5 and smashed the glass:( but hey ho thats what insurance is for lol
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I used the disco heater pipes and just loosened the clips and twisted them round and then just cut to length, another easy job :)
 
i havent got any pics but i had to cut and weld the front rad brackets to make the disco one fit which was easy enough and i also remived the egr valve....... Blow torch, plus gas and i even downloads a bilbe app... Just in case :)
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Guessing you didn't save the axles off the Disco? :doh:

My 90 has had a similar conversion, I really wish they'd gone the whole hog and used the Disco axles (all round discs, alloys fit without spacers etc). Job for next year if I can find a decent Disco to break.

Good work otherwise, what are you planning regarding gear/transfer box levers?
 
shame i tried to list in the for sale section but couldnt as i had under 50 posts :( i changed the rear axle already to disk but kept the front as i was the ashcroft 2 wheel drjve conversion and you need the older front axle for it to work with the locking hubs.... Sorry but on the up side my donor pos cost me 560 so you could get one flog the engine gearbox etc and keep the axels and break even after scrapping the shell and parts :)
 
Oh and i have 30mm spacers so i could use a lovely set of 300tdi alloys that i had powder coated black :) think they cost me 180 ish but worth every penny
 
You will find that tilting the rad back a little at the top will help the hoses and oil cooler pipes fit without modification.:)
 
cheers :). i did notice that when i put everything in place so when i welded the pins on top for the rad support brackets, i moved them forward rather then central........i was very surprised how everything except fuel lines fitted really nicely
 
little update....middle silencer fitted.....all wiring done.......fluids topped up/filled up.......only got the intake to do before ill start her up....i have a question for anyone who knows........is the crankcase a positive system...i.e does the breather hose attach to the post airfilter tubing so that the crank case gases are drawn into intake?
 
chrisrawe said:
is the crankcase a positive system...i.e does the breather hose attach to the post airfilter tubing so that the crank case gases are drawn into intake?
Click to expand...

The hose attaches after the air filter so as not to fill the filter with oil vapour.

Nice work by the way ;)

Any chance of a couple of pictures of that canvas truck cab? I'm looking at fitting one to mine at the moment. :D
 
no worries i'll take some pics for you iam over there tomorrow........cheers i did a bit of a bodge job when the v8 went in so this time i want everything near as damn it perfect so i dont have to tinker every spare moment to fix or repair the bodges i did in the first place :)
 
its a bit dirty and i still have all the crap in the back but heres a few pics of the roof for you..... Fits really well and isnt that bad in the winter either :)

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