defcrazy

defcrazy

Active Member
hi all we have a 1994 300tdi 90 and the gearbox is shifting hard from 1st to 2nd no other problems but we have two boxes from 300tdi discos will they fit / because the shifters on the disco box will end up being under the middle seat from what i see .can the def shifters bolt to the disco box i tried this but there are some slight diffrences between them maybe i missed something or some trick to get it to work an info on this will be a major help thanks
 

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i have fitted a disco r380 into my 110 as my one had worn out the tail shaft splines, needs a "spigot" making to lengthen the disco gear change rod inside the box then just bolt everything off the 90 box onto it. Can send you a copy of the drawing if you need it.
 
not had chance to scan, but here are the dimensions
overall length = 52mm
overall dia =25mm
bore of 15.95mm to a depth of 22mm at one end
shank of 15.95 to a length of 21mm at other end,
remove disco gearchange quadrant and measure how far along the bored end of the spigot needs drilling and tapping to 8mm for allen grub screw - Disco grubscrew is vertical
Remove defender gearchange quadrant
fit spigot onto gearbox selector shaft, slide defender quadrant onto spigot and tighten grubscrew - checck gearchange works through all gears, remove quadrant and spigot and drill a hole in spigot on the marks that the grubscrew has left. Took me 2 hours to work it all out and then make it.
 
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ok thanks for that i will try to work that out ...so the disco selector shaft is shorter and needs a piece to lengthen it then put the def gearchange quadrant on it ...right?? but a pic or drawing would be a big help its hard to imagine what your discribing in my head .. we have done this kind of things before but it will save alot of time knowing exactly what someone has already done to fix it .
 
it is an extension as the disco quadrant is longer and the stick goes into it centrally - the defender stick and quadrant are further back, plus the disco quadrant works on the top of the selector shaft and the defender works below the centre line - reverse action on the defender as it has the gearstick on a remote. Yes it does need the defender quadrant fitting into the disco box - remove the reverse gear stop and spring mechanism first from gearbox as it gives you better access to the grub screws, my defender grubscrew broke when undoing it so had to be drilled out, but other than that it is a straight forward conversion to do. Mine has now done 1000km without any problems, so it does work ok
 
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the drawing is easy to do yourself- draw a rectangle of 52mm by 25mm, then from the rear end come forward by 22mm and show a bore of 15.95mm dia. from the front go backwards by 21mm and show an outline of 15.95mm outside diameter. All made from a bar of round steel
 
just an update.... i had the adaptor machined to fit the defender gearlever but it needs a little adjustments so when i get it back from the shop i will post some pics of it for others who may want to do this conversion
 
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