Disco 200tdi motor to series gearbox

[Paul-88]

I have a disco 200tdi motor almost ready to transplant intp my series 3 .
Have seen plenty of comments that say it goes straight onto a series gearbox , trouble is mine wont !
The problem is that the four long bolts that pass through the bottom of the flywheel housing and bolt into the block do not line up with any bolt holes on the series gearbox bellhousing . Has anyone else had ths problem ? Have you drilled / machined the series bellhousing to allow the 4 long bolts to pass through ? Also does anyone know if a series clutch will bolt straight to the tdi flywheel  ? Any tdi transplant info would be much appreiciated .
 
   Thanks , Paul .

[MattMatt]

Mine did - I did tap one new hole in the TDI to the right just below centre but other wise it lined up perfect.
You can't use the Disco clutch plate and the splines are different so I just used the series plate.  Works fine!!!
Any pics of what won't line up?

[Paul-88]

Thanks for the reply .
  The stud on the one side that doesn't line up : Just like you Ive tapped the hole in the tdi flywheel housing and moved the stud accordingly , so it lines up with the series bellhousing - I thought this was all that was required . I'll come back with some pic's as soon as I can get sorted ( only joined the forum yesterday).
 Thanks again for the reply , Paul .

[ian_s]

all i had to do with mine was slot it straight in.
i used the series 3 clutch plate with the defender pressure plate, works really well.
i had to redo the drivers side engine mount, and also make some radiator mounts, and make an exhaust.
dont try and use a series exhaust, it is just toooooo small and will restrict the engine massively.

[MattMatt]

Found a pic of mine - from the gearbox side - new bolts

[muddyjames]

This sonds like a great convertion. If I ever get a series landy again I would consider doing this.

What is the oise levels like? Are they reduced from the old 2.25 diesel? I imagine it would go alot better?

Would a tdi gearbox fit but with the long gear lever still?

I love series landies but also do alot of towing hence why I have a disco now. Im guessing with a tdi engine and if you converted the axles to tdi ones as well to discs all round it would make a pretty good tow truck?

[MattMatt]

What is the oise levels like? Are they reduced from the old 2.25 diesel? I imagine it would go alot better?

Would a tdi gearbox fit but with the long gear lever still?

I must admit mine doesn't seem any quieter - but it's not bad.
I'm just about to change to an LT77 gearbox as the chassis I have has got the holes already there.  I don't think the long gearstick will fit though so I'm going to use the LT77 ones and change the gearbox tunnel.
Generall it is a great conversion and I'm lovin it!!!!

[Rich_P]

I love series landies but also do alot of towing hence why I have a disco now. Im guessing with a tdi engine and if you converted the axles to tdi ones as well to discs all round it would make a pretty good tow truck?

And then have to fit wheel arch extensions etc. etc. etc. and before you know it, you might as well of just bought a 90 or 110 straight off.

[ian_s]

my 200tdi is definately louder
but it has a side exit exhaust, with no silencing, and a k&n filter straight on the front of the turbo. it sounds really sweet

[chaosego]

would it be fairly easy to put auto tdi set up and keep the 2/4 wheel drive set up ?

[Paul Woodward]

You can use the auto box with the LT230 transfer box.
The LT230 can be converted to part time 4wd either with a kit from Ashcrofts or with some creative diy engineering.
The problem is the auto with transfer box is a lot longer that the Series box so it means moving the engine forward, moving cross members and making one off props just for starters.
It will be a bit easier with a 109!

[Paul-88]

Sorted.........The mystery 4 bolts in the bottom of the fly-wheel housing are only fitted to late model 200tdi's . Assuming that land rover fitted them for good reason I have counter- bored the flywheel housing and recessed 4 cap head bolts in there place , the matching position of the studs on a series 'housing have then been drilled and tapped out to accept standard M10 studs . Other than pulling out a couple of dowels ( 2 second job with mole grips ) , and tapping out a blind hole , thats it ! the gearbox now fits no problem .
Clutch is dead easy to sort (already done ) ............9 1/2 inch , series 3 diesel friction plate under a discovery cover plate bolts straight up .