Discovery 300Tdi - Swap Manual for Auto

[Iain_B]

I have a manual 300Tdi and a the little lady will be driving it, I will be replacing the R380 box with a ZF4HP-22 auto box out of a Japanese wrecked 300Tdi. I already have a low mileage transmission, transfer case, pedal box, shifter, wiring harness ( and will soon have the flex plate, gaskets &, kickdown cable). What else do I need?

If anyone has already done this, I would appreciate any tips or pitfalls you came across.

[matti4556]

Ian B - One thing comes to mind - Tranny cooler and pipework.
If you get the chance to route your own pipework :o(that sounds SO WRONG!), keep it away from the exhaust. It is my next project to remove the solid pipework and replace it with slightly longer flexible lines and bolt it up and away from the block/exhaust. I have no idea why they designed it that way, but the pipes run adjacent to the exhaust for at leat 3 feet on their way to and from the cooler at the front of the rad. - Matti

[justinc]

Urgent note!!!!!!!!!!!


I think there may be BIG problem, The japanese wrecked 300Tdi has an electronic 4HP22, and is not compatible with our engines, it needs inputs from the engine ECU, and our Tdi's don't have one in this country. All jap disco1's had EDC (Electronic diesel control)Tdi's, with flyby wire throttle etc. You will notice that it doesen't already have a kickdown cable....Thats because there is no provision for it with an electronic valve body.


I would imediately check the g'box for electric solenoids etc to confirm this.

JC

[mcrover]

I was about to ask, how what and where do you get these transmissions but from what Justins just said, I dont know if I want one now.

Mine is getting a bit tired so I was hoping to get something S/H to fill the time in while I rebuild mine.

[Iain_B]

Mine has a kick down cable - it has to be replaced as they cut it when took the engine out.

[justinc]

Whew, I'm glad it isn't what I thought it was!:o

I have been involved in wrecking/ repairing several EX Japanese D1's,(Both 1997 models) and both had EDC 300Tdi's and electronic controlled 4HP22's. This is due to Japans strict emission laws, there are no smoky old mechanical pumps on 300Tdi's over there . There is another explanation, apparently LR also bought out a 'part EGR' 300Tdi, with a mechanical pump, throttle cable and kickdown etc, but the pump had an electronic rack sensor and EGR ECU, a TPS attached to the pump throttle shaft etc etc etc . Looks horrible! Wonder if this was what your box came off? These D1 engines would've been 1994 to about 1996 From memory.

Not sure then what yours is then IanB, could you post pics then? Just in case there IS a slight difference. I am now intrigued.

Fiting the new kickdown cable requires removal of the valve body, not a job for outdoors, as the auto's interior needs to remain surgically clean. You will need a T27 Torx bit, and patience. Make sure you take note of where the different length bolts go.....


JC

[sniegy]

If the gearbox matches up & runs with the electronics which i doubt;), u may be able to run factory cruise control on ya 300tdi, all u will need is the ECU, s/wheel switches &.???:D:D

Something i wanted on mine till i found out all the prices for the factory unit & gear..:eek:
The good thing about them is u dont get that big plume of smoke on start up..:)

All the best.

[justinc]

If the gearbox matches up & runs with the electronics which i doubt;), u may be able to run factory cruise control on ya 300tdi, all u will need is the ECU, s/wheel switches &.???:D:D

Something i wanted on mine till i found out all the prices for the factory unit & gear..:eek:
The good thing about them is u dont get that big plume of smoke on start up..:)

All the best.

Hi Sniegy,

I have all the bits ....Except the ECU, throttle pedal and harness, which I can probably get sent if you are interested.

I would personally stay clear of these as the injector pump costs a fortune to rpair if it fails, a similar pump on the freelander is about $3000 to rebuild apparently...:eek:

JC

[sniegy]

Thanks JC,

I dont own that 300 anymore...But thanks for the offer.;)
I spent some time trying to track parts through work & spoke to a few guys in the UK (prior to AULRO).
The things u find out when its too late:cool:

[cookiesa]

The partial one would have been the one available in New Zealand also perhaps? Can't remember where but I remember reading about NZ D1 owners talking about blocking there egr systems

[Iain_B]

I'll take a few photos tomorrow night if I get home early enough. I got the transmission + the rest of the stuff from a Jag and Landrover wrecker in Acacia Ridge - he doesn't have anymore unfortunately and they are getting a bit scarce.

Regarding the electronic controls, I fitted 4L80E box into my XJ-S V12, I used a TCU unit from PCS, full programmable via a laptop and works on a whole range of transmissions right up to the latest ZF 6 speeds. I have no doubt you could make any electronically controlled tranny work with it. I've programmed mine even to have paddle shifts ( just have to find a nice paddle shifter) and I've programmed in two separate shift patterns, dyno mode which locks it in one gear, snow mode ( hich cancels first gear. the TCU costs $1500+ import taxes.

http://www.powertraincontrolsolutions.com/catalog/index.php?cPath=21 (PCS TCU)

[cookiesa]

Don't know if you could make it fit but Toyota had a nice set of paddles on the Celica