Wild Disco Transplant

[oldturkey]

I have a '94 Discovery transplanted with a Toyota 1KZ 3.0 Turbo Diesel and matching autobox. My mechanic in Bangkok has problems mating this to the LR transfer box (the splines chew up in the input gear), and so I am managing with an old part time 4wd Prado box, which is geared 22% higher than the LR original (1:1).
It takes off from the lights like a rocket (leaving many red faces behind, to my delight), but when it changes into top at about 105km/h (2,000rpm) it starts to struggle.

This engine has no intercooler, and seems very badly designed to me, with an alloy U-tube looping over the engine top, linking the turbo to the intake manifold. This tube actualy functions as an INTERHEATER !
Early Prados used this engine with an intercooler on top, with resultant 25% better power & torque. I would like to make this modification, but cannot obtain parts. ANY IDEAS? Would any other modifications / adjustments be necessary?
The beast is also very quirsty @6to7km/litre ; there are 2 possible reasons for this:
Excessively high gearing making the torque-converter work overtime?
Lack of FW hubs; can FW hubs be fitted to Disco axle?
The mechanic has done over 70 of these transplants, the eldest 3 years and still going strong.

[mcrover]

Nice conversion but I would have thought you could have possibly plumbed a 300TDI or even a TD5 intercooler in.

As far as the transfer case goes, sorry I cant help you.

[Slunnie]

For the intercooler parts, perhaps you could have them posted by an auto dismantler from another country to you. I'm sure some of the Australian ones would be happy to do it.

Also, with the gearing, does this take into account the differences in tyre size and diff ratios already? Perhaps there is also the option of fitting 4.11 diffs to the Rover axles.

[Jojo]

Lack of FW hubs; can FW hubs be fitted to Disco axle?
The mechanic has done over 70 of these transplants, the eldest 3 years and still going strong.

The Disco has permanent FWD, hence no freewheeling hubs. I read about a moron (pardon me) who sells conversion kits for Land Rovers to make them selectable FWD vehicles and, yes, they apparenly had those hubs as well. I just don't see the point of the conversion in first place.

Cheers