How hard to change td5 to 300 tdi

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Spoonofinsanity

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We have enough bits to make a dodgy disco td5 minus the engine as it blew up quite nicely the truck is only gonna be used as an offroad work vehicle - towing trailers etc on festival sites so doesn't need another £1000 worth of td5 engine.
The 300 tdi uses the same gearbox but what do you actually need to bolt up[ to the td5 disco box.
Which clutch and flywheel? different bell housing?
Cheers in advance
 
same difference though isn't it…………

its just a reverse mod :doh: so if you need to put an adaptor on the bellhousing to fit a 300tdi to D2 R380 then you need to put an adaptor on a TD5 to fit D1 R380 and so on…..
 
Hi guys yes i was meaning convert a disco 2 to 300tdi.
Adapter plate?
Surely you can swap the bell housings just had a look at the disco box in the corner of the workshop and the bell housing does unbolt- is there a significant difference in the bellhousing lengths?

The main problem i can see is input shaft is most likely different?

Without having both a disco 1 300 box and the td5 box sat side by side i don't know all the differences.

So it would be easier to just take all the gear from a disco 1 cut and shut mounts into the disco 2 at least that way you get difflock on the disco1 setup. Or just scrap the disco 2 keep as many bits as poss for spares on the running disco 2 and buy a disco 1 cheap for site abuse.

Anyway i'm gonna go have a read of the suggested thread
thanks
 
For anyone interested this seems to be a much better thread for my interests but he ripped the disco 2 gear out like i suggested and replaced with disco 1.
It also states the input shaft must be changed aswell as the bell housing.
300 tdi into d2
 
to be honest if its just going to be a workhorse then why bother? Sell the TD5 as a spares/repairs and go buy a 300TDi, would be much easier and cheaper!

or get a Shogun for £500, most reliable ****ters going!
 
bankz5152 said:
To be fair im quite interested in this. Ive considered putting a 300tdi in my TD5 with a Puma 6 speed gearbox.
Click to expand...
Did this about 2 years ago and its been just awesome. However, getting the instrument cluster to function, (temperature, speedo and rpm readouts) was a major ball ache. Mine is a 200tdi though, and its coupled to an autobox.
attachment.php


Installing the A/C was an afterthought so you'll have to excuse the rather untidy pipework.
 

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ifloochies said:
Did this about 2 years ago and its been just awesome. However, getting the instrument cluster to function, (temperature, speedo and rpm readouts) was a major ball ache. Mine is a 200tdi though, and its coupled to an autobox.
attachment.php


Installing the A/C was an afterthought so you'll have to excuse the rather untidy pipework.
Click to expand...
Can you remember how to get over them? I am planning to do mine.
 
Spoonofinsanity said:
We have enough bits to make a dodgy disco td5 minus the engine as it blew up quite nicely the truck is only gonna be used as an offroad work vehicle - towing trailers etc on festival sites so doesn't need another £1000 worth of td5 engine.
The 300 tdi uses the same gearbox but what do you actually need to bolt up[ to the td5 disco box.
Which clutch and flywheel? different bell housing?
Cheers in advance
Click to expand...

Youl need a 300tdi bell housing & fit a input shaft out of a box that came out a 300tdi so using a 300 clutch ect
the td5 has a longer shaft. It would be easier to fit the whole lot ie..engine & boxes & fit aftermarket gauges as its a ball ache to get them to work.
 
kevstar said:
Youl need a 300tdi bell housing & fit a input shaft out of a box that came out a 300tdi so using a 300 clutch ect
the td5 has a longer shaft. It would be easier to fit the whole lot ie..engine & boxes & fit aftermarket gauges as its a ball ache to get them to work.
Click to expand...
He ain't logged in for two years so probably busy welding his chassis back together.
 
Brookwood said:
Can you remember how to get over them? I am planning to do mine.
Click to expand...
Speedo works from receiving a signal from the ABS, so that works, fuel gauge still worked, it was getting the temperature gauge and tacho to work that was the main issue. To get the temperature gauge working, I kept the wiring loom and ECU in place, put an adapter into the bung on the thermostat housing for the replacement engine's coolant sensor and fit the original td5 coolant temperature sensor. The coolant temperature was then relayed through the ECU and worked like stock. Still haven't gotten the tacho to work, but got a new member of the family just around then, and haven't really spent quite as much time working on the car. My plan back then was to graft a reluctor ring on to the flex plate and use a hall effect sensor mounted on the 200tdi auto transmission to pick up engine speed. Funny enough, there's a casting on the bell housing that looks like it was meant for the purpose. Anyways, hoping to get around to doing it some day before retirement.:p
 
ifloochies said:
Speedo works from receiving a signal from the ABS, so that works, fuel gauge still worked, it was getting the temperature gauge and tacho to work that was the main issue. To get the temperature gauge working, I kept the wiring loom and ECU in place, put an adapter into the bung on the thermostat housing for the replacement engine's coolant sensor and fit the original td5 coolant temperature sensor. The coolant temperature was then relayed through the ECU and worked like stock. Still haven't gotten the tacho to work, but got a new member of the family just around then, and haven't really spent quite as much time working on the car. My plan back then was to graft a reluctor ring on to the flex plate and use a hall effect sensor mounted on the 200tdi auto transmission to pick up engine speed. Funny enough, there's a casting on the bell housing that looks like it was meant for the purpose. Anyways, hoping to get around to doing it some day before retirement.:p
Click to expand...
On a similar theme I helped a mate fit an LT77 out of a V8 Disco onto a VMDiesel ex a RRC, the VM had a completely trashed LT77, siezed due to no oil and the VC unit had siezed. We were on a tight schedule a nd found as well as a different bell housing the first motion mainshaft was slightly longer, so a decision was made with time in mind to simply cut the end of the pilot shaft diameter off with a 1mm thick cutting disc in an angle grinder. We had a lathe so we put the output shaft end of the gearbox, (transfer case removed), in the chuck, gearbox supported and 4th gear engaged, this turned the input shaft, running the grinder against the shaft the pilot end was cut to length neatly. Then all that was needed was to alter the length of the pilot shaft diameter, different disc and ground the diameter down on the end of the clutch plate engagement spline, the pilot end diameter was also bigger, the VM used a ball race pilot bearing, took that out of the flywheel and turned up a phosphor bronze replacement. All worked happily until the engine died a couple of years later, anything in mechanics is possible, not always suitable to the purist but absolutely possible.
 
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