IamRobbie · Jan 24, 2015

Ok so I've got a Td5 bulkhead complete with dash and everything from a mate of mine.

What I need to know is what will I have to change to make it fit my 90? I know that I need to cut a hole in the middle of the bulkhead for my existing loom to go through and I've read about a wiper motor hole being different but I don't think I need to do this as it has the wiper motor and wipers already on??

It also has the td5 heater still attached so will that work with my disco 200tdi engine? I would assume so as the pipes looked the same..

There are alot of wires everywhere and I hate wires but I'm unsure of everything that I will need..

I can get the tunnel and floor pans if need be..

Thanks

======================
My useful links for conversion

Installing a Defender Td5 Instrument Pack into a 200Tdi/300Tdi - Land Rover Technical Blog

http://community.evo.co.uk/forums/thread.cfm?threadID=48229

http://img.photobucket.com/albums/v686/paulmc0308/Electrical/2002-OldHazardWarningSwitch.jpg

jamesmartin · Jan 24, 2015

it will fit with a little modifications which will be obvious when you stand them next to each other and start swapping pars over

IamRobbie · Jan 24, 2015

What parts will I need to swap? The td5 one has everything on it as far as I can see... The pedals need swapping? As the td5 1 has wires on it, also the break pipes all go back to one place is this different? I'll have to have a good look at them both in guess.

jamesmartin · Jan 24, 2015

thats up to you in that case, then wiring will be different ,pedal boxes will work your brakes and clutch even if pipe work needs modding,so will heater etc

IamRobbie · Jan 30, 2015

James will I need the td5 tunnel, floorpans or seatbox at all mate?

IamRobbie · Jan 30, 2015

I'm going to use my existing wiring and probably existing clocks.

aaronmorris · Jan 30, 2015

IamRobbie said:
James will I need the td5 tunnel, floorpans or seatbox at all mate?

New I'd read something about this before.
Have a read of this, he chopped the td5 bulkhead a bit and fitted the lt77 tunnel diaphragm.
I'd do the same having read it again.

"Land Rover Bulkhead Swap" discussion on Evo Community

greyhair · Jan 30, 2015

im having a tdci bulkhead adapted to fit on my 1992 200tdi defender
i didnt want the vents in the bulkhead as the bulkhead i removed was gone all around this area, plus i was not to keen on getting an old bulkhead rebuild and galved but thats just me being fussy
will let you know what it looks like when i get it in 2-3 weeks
comes fully galved and undercoated ready for the paint shop

IamRobbie · Mar 9, 2015

How does it look bud??

I've been looking everywhere online at this setup and I've found I can use the td5 clocks with a bit of messing around...

My main worries are:

Using the whole td5 dash and clocks do I use the whole td5 wiper unit ect? It's all in one piece still (bulkhead dash ect)

How do I make the hazard switch work as they are different..

If I'm using my 200tdi steering wheel and indicator stalk ect I would assume it's just plug and play with my old wiring loom.

gse1986 · Mar 9, 2015

IamRobbie said:
My main worries are:

Using the whole td5 dash and clocks do I use the whole td5 wiper unit ect? It's all in one piece still (bulkhead dash ect)

How do I make the hazard switch work as they are different..

If I'm using my 200tdi steering wheel and indicator stalk ect I would assume it's just plug and play with my old wiring loom.

I don't think you've said which year td5 bulkhead you've got. I've got one of the earlier ones (W reg maybe?) and the hazard switch does work (my original one broke, so before I ordered one I tried the one off my td5 bulkhead and it works.

Wipers wise I'd use the TD5 one (even more so if you've got them there already).

I'd be interested in seeing how you get on, as I'm yet to fit mine. Maybe soon I'll get chance....

nobber · Mar 9, 2015

I fitted one to my 85 90, the tunnel will need cut to suit your diaphragm, its easy to do.
You will also have to drill holes for bolts for the diaphragm. In hindsight I would have put captive nuts on the bulkhead to bolt the diaphragm on , tack weld them on , otherwise removal is a right pain in the arse.

Apart from that and the wipers its pretty much a straight swap.
Don't know about wiring, I bought the bulkhead new when Land Rover were selling them off for 175 quid.

IamRobbie · Mar 9, 2015

Maybe James will know the difference if any between the indicator stalk of a 1989 90 and a 2001 td5...

I'm guessing I'll need to run the indicator wiring from the current small switch on the right hand side to the newer td5 hazard switch

IamRobbie · Mar 9, 2015

gse1986 said:
I don't think you've said which year td5 bulkhead you've got. I've got one of the earlier ones (W reg maybe?) and the hazard switch does work (my original one broke, so before I ordered one I tried the one off my td5 bulkhead and it works.

Wipers wise I'd use the TD5 one (even more so if you've got them there already).

I'd be interested in seeing how you get on, as I'm yet to fit mine. Maybe soon I'll get chance....

2001? Y reg....

Everything is on it. Steering wheel dash the lot. And brake services ect on the engine side. I'll start the wiring tonight if the mrs isn't on one when I get in at 7...

IamRobbie · Mar 9, 2015

found this, should work i hope

IamRobbie · Mar 9, 2015

started taking apart tonight, just come in...

The lower dash, it has no screws holding it in the very bottom but its stuck tight onto the bulkhead..... has the #### who owned it before me glued this to the bulkhead or should it be stuck like that??

aaronmorris · Mar 9, 2015

IamRobbie said:
started taking apart tonight, just come in...

The lower dash, it has no screws holding it in the very bottom but its stuck tight onto the bulkhead..... has the #### who owned it before me glued this to the bulkhead or should it be stuck like that??

Have you took the rest of the dash to bits?
If you remove the bottom tray there will be a couple of 8mm headed bolts holding the top of it to the bulkhead if memory serves me right.

IamRobbie · Mar 9, 2015

I'll have another go tomorrow night. Screws everywhere lol.

aaronmorris · Mar 10, 2015

Don't I know it. All different anorl

Hope you're remembering where they all go

To be fair, defender dashes are pretty simple. Are you removing all of it?

IamRobbie · Mar 10, 2015

I'll rip it all out or cut it out if it starts to **** me off lol. Td5 bulkhead and full dash is going in so i only need to remember where the wiring roughly goes as I've tagged anything and everything up where it belongs...

When I strip the td5 dash off that bulkhead I need to be careful lol

IamRobbie · Mar 12, 2015

all the wiring is out... omg... haha

thats my truck fooked...

haha

Just gotta get wings off and the bits off engine side and with a little luck i should have a mate pop round to life the bulkhead off and new one back on..

only worry is I'm unsure how to set the bulkhead gaps lol..

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