300 tdi r380 gearbox swap

[biggerlandy]

any day will start doing conversion into my 90 will do a step by step photo guide its a disco set up

[stuntman]

Just done one 

Finished last friday, taxed, tested, insured and notified with the DVLA.

Well worth the swap :)

If you need any tips let me know, I've had ALL the head aches with this swap.

[biggerlandy]

what did you do about gearbox levers position

[stuntman]

I left it as is.

I removed the engine, gearbox and trans box from the V8 110, (and promptly sold it)

Then removed the engine, gearbox and trans box from disco, and also the gearbox support member from the disco.

Fit the gearbox member to the 110, you may need to drill a couple of holes for the front of the cross member but nothing serious. Then go and chop off the disco engine mounts and fit them onto the engine.

Now drop the gearbox and transbox into the 110 and connect the props up. You will need to swap the transfer box rear out put flange and mount, so you can still use the defender gearbox ( only a nut and bolt job). This will also allow the use of a speedo cable.

Now support the front of the gearbox and go and replace the clutch on the engine, seriously it is worth it. ( I didn't and had the engine out 5 times).

Connect engine and gearbox together and lower the engine into the engine bay, level it up and tack weld the engine mounts. Lift the engine off the mounts and seam weld both sides of the mounts and cover in paint.

Drop back in and tighten everything up.

I also repalced the master cylinder (clutch and brake) a this point.

re-use the clutch pipe from the disco, it should be fine.

Now lower the mounts on the front cross member so the radiator sits level with the slam panel. Weld the radiator supports from the defender to the top of the radiator holder.

Other than a few fiddly bits it's done!

You will need to trim a few pipes on the power steering as the disco box moves the engine forwards a fair bit.

You can now get to the bellhousing bolts very easily compared to a defender!

I also replaced alot of the heater pipes with car heater hose as I'd chopped alot of it off to get the engine out.

Also be aware that the 300tdi may have the immobiliser on the fuel pump (black box with 3 wires going in).

If it has, drill the studs out or break it off as I did and you'll find the stop solenoid switch hidden behind it. I was really dubious to break this off but now I've done it I'll hapily break it off future engine :)

Best of luck and pm me if you need any more help!

[solihull-mick]

Just a small point, the disco clutch pipe wont work, as the thread in the master cylinder has a differnt pitch thread, get the correct 300 defender pipe or cut down the original one and reflare the end,, good luck

[biggerlandy]

i dont understand what you mean about mounts on gearbox so you  can use defender gearbox i dont want to use defender gearbox i want to put disco gearbox in   dont worry new clucth going in and engine is striped down at mo to replace all seals etc

[stuntman]

Hello chap.

I did use a new 300tdi defender master sylinder and the disco clutch pipe, worked fine.

I also used the disco r380 gearbox. You will need to unbolt the defender's existing crossmember and swap it for the disco's one, so you can mount the disco bearbox.

Sorry I may not have made that too clear.

[biggerlandy]

i take it in using disco crossmember the gearsticks line up in normal hole in gearbox tunnel

[stuntman]

No mate.

You will need to fabricate a new tunnel, I chopped up the old one and fibre glassed it over.

You need to use the disco gearbox crossmember as the disco gearbox will not fit onto the defender crossmember.

So, disco engine box and trans box, will fit with the disco gearbox cross member and the disco engine mounts. You will also need to lower the radiator mounts.

[biggerlandy]

ok cheers