thebiglad · Sep 7, 2014

Hi all, well I got back from UK at about 12 mid-day today so after having a little refreshment I reckon it's time to start my own re-build thread.

So where do we start, well she's a 5 speed manual, re-mapped by TD5 Alive, de-EGR'd, Samco hoses and drives really well. 150,000mls.

Here's a few pics of her today:

She has a number of mechanical and electrical issues that I will be putting right over the coming weeks.

1. Little or no assistance on the steering?

2. Gear lever (manual box), the lever gets stiff to select gears after a long motorway run.

3. Replace all brakes;

4. Replace all shocks;

5. Optimise fuel performance - already very good even though she has not been loved in a long time !

I want to end up with a smart, reliable Discovery TD5 tool.

OK so to kick things off, the pas problem.

The pump appears to be pumping although I don't know at what pressure. I slightly undid the hydraulic banjo on the HP (high pressure) output from the pump and as soon as the engine was fired up there was atf EVERYWHERE !!!

I tried to bleed any air out of the system (she has new pas pipes recently) by swing her from lock to lock but that made no difference.

There is movement within the pas reservoir.

There is no serpentine belt noise.

There is slight assistance if I keep the revs up, but it's far from right.

I'm going to try bleeding via the bleed screw on top of the steering box.

Anyone got any other ideas to help me diagnose the problem, please? This is my priority right now as I've just driven about 1000mls the way it is, and it wasn't funny.

Cheers
Dave

DiscoPol · Sep 7, 2014

nice little mota but in't the steering wheel int wrong place?

johnlad · Sep 7, 2014

steering box been adjusted to much making steering to stiff

thebiglad · Sep 7, 2014

johnlad said:
steering box been adjusted to much making steering to stiff

It could be that but when I first picked it up it seemed pretty-much OK. Seems worse once the atf has warmed up????

What I'm going to do this week is get the front up end in the air so I can turn lock to lock without putting any strain on anything.

I would have sworn it was the pump and it just feels like that - assistance is sometimes there, sometimes not. Never there enough to do tight manouvering though.

thebiglad · Sep 7, 2014

DiscoPol said:
nice little mota but in't the steering wheel int wrong place?

HI DP, yes you're right it is a right-hooker that I've just picked up in England. The same thing in France (LHD)would be 2 - 3 times the price

DiscoPol · Sep 7, 2014

thebiglad said:
HI DP, yes you're right it is a right-hooker that I've just picked up in England. The same thing in France (LHD)would be 2 - 3 times the price

I feel your passion buddy, same here 3-4 times the price, and now mine is dying I'm thinking of popping over and buying one myself and swapping over all the bits to make it lhd again

thebiglad · Sep 7, 2014

She's got a few little problems that I'll have to work through, but she drives really well (re-mapped) and is extra-ordinarily economical.

I was running down from UK today, about 1100kms at an average of 100kph and she consumed diesel at the rate of about 6-7ltrs per 100kms !!!!

Just amazing and with loads of grunt too.

She's worth saving and I reckon she'll make a REALLY nice car when she's done.

Dave

auf_wiedersehen_pet · Sep 7, 2014

thebiglad said:
I was running down from UK today, about 1100kms at an average of 100kph and she consumed diesel at the rate of about 6-7ltrs per 100kms !!!!

What's that in real money?

Tidy looking Disco Dave.

thebiglad · Sep 7, 2014

auf_wiedersehen_pet said:
What's that in real money?

Tidy looking Disco Dave.

I'm not sure that I dare tell you mate

The last time I talked about what I was getting from a Disco I nearly got lynched !

7ltrs of diesel per 100kms equates to roughly 1.5gallons per 62 miles so about 40-ish mpg.

I understand that most won't believe me and I don't really care. This was one long run so optimum conditions. Running at about 65mph on average. That's what it (she) consumed.

Dave

Disco DJ · Sep 7, 2014

I get constant 30mpg out of mine. Short journeys and thrashing it. So I'd imagine its possible.

td5nut · Sep 7, 2014

thebiglad said:
I'm not sure that I dare tell you mate The last time I talked about what I was getting from a Disco I nearly got lynched !

7ltrs of diesel per 100kms equates to roughly 1.5gallons per 62 miles so about 40-ish mpg.

I understand that most won't believe me and I don't really care. This was one long run so optimum conditions. Running at about 65mph on average. That's what it (she) consumed.

Dave

I got a 2000 td5 xs with a mastaz ecu,recently I got 350 miles to 1/2 a tank on a and b roads on a run back home,regular doses of forte help.

MJI · Sep 7, 2014

If it is ATF wrong oil

Uses some expensive cold climate stuff

ATF takes out the seals

cambridgecockney · Sep 8, 2014

Change fluid. my previous did this, thought at first steering pump.fluid was brown rather than red. all ok after a change.

biolandy · Sep 8, 2014

Looks nice Dave-worth changing fluid first to see what that does

MJI · Sep 8, 2014

Oil should NOT be red, more like a pale green

thebiglad · Sep 8, 2014

MJI said:
Oil should NOT be red, more like a pale green

Thank you for your input MJI.

The green stuff you refer to is Land Rover's own formulation and is called something like "ACE & PAS Cold Climate fluid". In other words it is an hydraulic fluid (like atf) but formulated to be OK in really cold climates. I think they decided that this cold climate business was a requirement in view of all the ACE pipework 'hanging out in the breeze' whereas the pas pipework is in the engine bay being kept toasty.

It is also approx 3x the cost of ordinary atf.

I think the first thing I will do is what Cambridge Cockney and Biolandy suggest and change out the fluid, then see where we go.

@ MJI - where did you get the info about atf affecting the seals? Not seen that before and would like to know more. Also bearing in mind that the same steering steering box is used in the Disco 1 and it uses Dexron atf?

Right lads, I'm off out on the Bonny to go and get some more pas fluid.

Cheers guys,

Dave

MJI · Sep 8, 2014

thebiglad said:
Thank you for your input MJI.

The green stuff you refer to is Land Rover's own formulation and is called something like "ACE & PAS Cold Climate fluid". In other words it is an hydraulic fluid (like atf) but formulated to be OK in really cold climates. I think they decided that this cold climate business was a requirement in view of all the ACE pipework 'hanging out in the breeze' whereas the pas pipework is in the engine bay being kept toasty.

It is also approx 3x the cost of ordinary atf.

I think the first thing I will do is what Cambridge Cockney and Biolandy suggest and change out the fluid, then see where we go.

@ MJI - where did you get the info about atf affecting the seals? Not seen that before and would like to know more. Also bearing in mind that the same steering steering box is used in the Disco 1 and it uses Dexron atf?

Right lads, I'm off out on the Bonny to go and get some more pas fluid.

Cheers guys,

Dave

A LR specialist told me that ATF could mess up part of the PAS system

thebiglad · Sep 8, 2014

MJI said:
A LR specialist told me that ATF could mess up part of the PAS system

Then I would have to say that he doesn't know his trade. Dexron atf is used in almost all car p.a.s. systems in the world.

thebiglad · Sep 9, 2014

So, I've been delving into the hydraulic circuit of the steering system and found something odd. On all the pumps I have seen there is an adaptor ( a large nut looking thing) on the pump HP output side. On my pump I have a std looking banjo. So I'm a bit concerned about finding a replacement that will fit my pipework.

Doh !: I've just realised that I am mistaking the ACE pump for the pas pump which is below it. I really shouldn't be let out on my own

I tried bleeding/emptying the system today, via the bleed screw on the steering box. I got some oil out but not enough (the whole circuit contains approx 3ltrs of fluid) so I'm leaning towards a fubar'd pump. Just a shame they cost £150+

I've got some TD5 viscous fan spanners on order so as soon as they arrive I can get stuck in.

Cheers
Dave

biolandy · Sep 9, 2014

Dave not sure if this could apply to a TD5(not had to mess with mine yet),but when I renewed my ps fluid in my Mondeo,I took off the belt off,and wrapped a piece of blue polypropylene rope twice round the pump pulley.I diverted the return hose to an empty container and plugged reservoir fitting with poly bag and elastic band.Then keeping reservoir topped up,I tensioned the rope and pulled to rotate pump-then release tension and pull rope back ready for another go etc etc(keeping an eye on reservoir level and topping as needed).
Carried on like this until clean "new" fluid showed at outlet-was surprisingly quick and "all going on in front of you"-none of this crawling underneath stuff.

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