PDA

View Full Version : Clarkie's County Auto Conversion



sclarke
12th May 2009, 03:17 PM
Guys,
Been ages since i started this project and i've got thru all the little projects stopping me with this big project.

So i guess i should explain what it is i'm doing?

Simple............. Putting a ZF Auto in a County...

Here is the original pix of it when i got it.
https://www.aulro.com/afvb/images/imported/2009/05/843.jpg
https://www.aulro.com/afvb/images/imported/2009/05/844.jpg

2 years ago, i bought this county and the plan was to put a 3.9 and Auto in it.
Since then the plans have changed alot, it was changed to a 4.2 Stroker with motec and Crawler gears in the transfer, then it went back to a 3.9, now its a 3.5 with ZF.....

Why the 3.5 and ZF?? Simple... i scored a rebuilt 3.5 and ZF for a good price.
2 years back i pulled the LT85 out of the county and sold it.
So now it was time to get this thing finished...

sclarke
12th May 2009, 03:22 PM
I pulled the 3.5 and ZF from a rolled RRC i scored. the previous owner told me it was rebuilt about 20k ago. receipts have proven that and a check over of the engine confirmed it. I pulled the Input gear out of the transfer to check for wear to find it had none. So that went back together and the gearbox and transfer were left attached to the engine. No need to seperate them for the installation and no need to worry about oil leaks as it has none.

https://www.aulro.com/afvb/images/imported/2009/05/838.jpg
https://www.aulro.com/afvb/images/imported/2009/05/839.jpg


I pulled the rocker cover and Valley off to have a squiz... Mmmmm Nice and Clean....
https://www.aulro.com/afvb/images/imported/2009/05/840.jpg
https://www.aulro.com/afvb/images/imported/2009/05/841.jpg


A New valley cover gasket and manifold and Carbs were bolted back on.
I did nto know if i wanted to go SU or CD strombergs, but i knew the Strombergs worked on the county when i got it, so i opted for them.
https://www.aulro.com/afvb/images/imported/2009/05/842.jpg

sclarke
12th May 2009, 03:27 PM
Time for the engine out of the county to come out.
https://www.aulro.com/afvb/images/imported/2009/05/835.jpg


I'll use some of the items off it, but at this stage it will be sold or become land fill.....

I then had the fun task of cleaning 25 years of oil and dirt from the engine bay, the old engine had a leak and so did the power steering... so it was really bad...
Karcher and some killer degreaser fixed that problem.
https://www.aulro.com/afvb/images/imported/2009/05/836.jpg
https://www.aulro.com/afvb/images/imported/2009/05/837.jpg

the power steering box i'm scrapping and using a 4 bolt from a RRC

sclarke
12th May 2009, 03:31 PM
The new engine was dropped in place and all the mounts fitted up.
https://www.aulro.com/afvb/images/imported/2012/09/527.jpg

Make sure you use the county mounts... the transfer mounts on the RRC and disco are different.... i found out the hard way and had to look thru 2 years of Landy parts to find the originals....

https://www.aulro.com/afvb/images/imported/2009/05/833.jpg
https://www.aulro.com/afvb/images/imported/2009/05/834.jpg

sclarke
12th May 2009, 03:43 PM
Time to fire it up and see if it accually runs again.....
before i could do that, i had to modify the wiring and make the RRC distributor work. i'm running a RRC dizzy as i have a few spares and they are alot nicer than points... or the old County Electronic dizzy.
That took some time as the wiring had been modified some time ago for a after market dizzy. Then came the sorting out the LPG and fuel system. The LPG solenoid wiring was repaired and as was the fuel cut of solenoid. that in its self took me over 20 hours to neaten up the wiring and i'm still not finished...
I'm running the EFI exhaust manifolds and efi pipes to the 1st muffler, from there i will have a new exhaust fitted... i was going to put a set of extractors on it, but have opted out as the HP gain and note is not noticable ive been told. A good exhaust on the efi manifolds will perform and sound as good as any extractor system.

A V8 twin Falcon Thermo fan setup was put on the radiator and it was test fitted and then it came back out.

Then the power steering box was changed over. This is not easy, as the RRC and disco reservoir is on the LHS and the county is on the RHS, so i used the RRC pipe from the pump the the steering box and i used a cut hose disco pipe assembly from the steering box to the reservoir, then i bought some 5/8 hose to go from the reservoir to the power steering pump.

The Air conditioner is staying so i have to change the lines around to match the RRC compressor, this i will do later....

Radiator went back in and i test ran it.

Opps, best i fit an exhaust.... its loud....

https://www.aulro.com/afvb/images/imported/2009/05/832.jpg

sclarke
12th May 2009, 03:56 PM
Things i have found so far.

County gearbox cross member is not replacable with a RRC or Disco. It is unique to a county.....

Transfer case chassis mount on the drivers side is different to a RRC or disco.

if you use a EFI exhaust it has to be one that runs over the cross member, a Disco one will not fit.

The Transfer case shifter on the RRC fits in the county, but fowles on the center hump.... i have to soft this one out.

The Gearbox cross member is really close to the auto pan... i might have to modify the cross member.

And i have not even thought about the Auto shifter placement yet.
I am thinking about buying the Ashcroft auto console, but at $1000 landed.... i might not..


Other things i have done to the car, but dont have pix of...
Rear diff is a 130 Disc rear end, with ARB locker and Maxi axles.
New parker, indicator and stop lights. Oh and a defender reversing light.
I have a Bearmach swing away carrier, not yet fitted.


Things i need to do and not in order....
Connect the tail shafts
Replace the front diff, i'm going RRC at this stage due the availability of cheap CV's
Exhaust
Interior, shifter mount and center hump back in.
LPG, get it reconnected and working
plus stacks of little things...

I can then test drive it and see what else it needs......

Transfer will get the Crawler gears fitted, i just have to get it going 1st.... its $1500 i have sitting on my floor that needs to be finished off...

So anyway, i'll keep plodding along and if all goes well, it will be finshed before my trip in August....

Clarkie

McDisco
12th May 2009, 04:51 PM
Looking nice a neat Clarkie. I think when I finally get my rangie I might be needing your technical skills. I am looking for a house at the moment...perhaps I should move to to Mooroolbark?!

Angus

Slunnie
12th May 2009, 05:08 PM
Clarkie, I'm liking this a lot and will follow with great interest!

I've encountered many of the same issues when fitting a 3.9/ZF/LT230 to a Series. Here were my solutions if they are any help.

Shifter next to transfer lever for some of that Er..... Erg..... Ergo.....Ergonom...... oh never mind.

Also the handbrake I changed to a Discovery unit and moved it from inbetween my legs.

https://www.aulro.com/afvb/images/imported/2009/05/831.jpg

sclarke
12th May 2009, 05:40 PM
Slunnie, interesting.....

my 1st thought was to have the shifter where the center console box is, but i like the cubby box, so then it was where your placing yours... i was thinking of a nice alloy box for it to sit in, or i might make a steel one...

But the location is about right as you dont want to lean far to shift gears...

But the B&M or Hurst shifters on a custom bracket would look fully Sick mate....

http://www.rocketindustries.com.au/images/brands/b&m/BM80685.jpg

Slunnie
12th May 2009, 06:07 PM
Very narce! :D

I used a factory selector because I knew the movement would match the transmission etc and there would be no mucking around. The other consideration, is that the selector cable come out of the selector in a way that may not work with the spacer if you want to run that.

The handbrake can also be fitted in between the front seats and still fit the cubby boxs that are sold on Ebay with enough hand clearance.

https://www.aulro.com/afvb/images/imported/2009/05/829.jpg

MacMan
13th May 2009, 07:58 AM
Good to see the digit has been extracted Mr C!

Will be the mother of all Mum's Taxis when fully cooked.

sclarke
9th July 2009, 06:35 PM
OK time for an update. Pix to come

When you use a Disco Transfer you need to move the Transfer Shifter forwards 50mm to be in the exaxt spot the LT85 transfer shifter was.
So i made a plate and moved it forwards 50mm, i had to then lengthen the selector rod and Diff lock linkage....
Then i refited the transfer hump with the old rubber boot. i will work out a better way, but will do for now.

During the week ive sorted the shifter location.
Between the HL selector and the hand brake.
Keeping the county hand brake for now.
I made a braket and used the mounting plate from a Disco, so i can use the disco selector and trim.

Kick down cable..... this took some doing...
Used parts from an injected auto Rangie and cut and welded and played around and got it to work. The length of the pivot was the key issue and had to be spot on, at full throttle the cable is stretched to its max.
This might have to played with.

Only 1 million things to do....
Hoping to have it ready for the border track trip, if not the Rangie will be going....

sclarke
10th July 2009, 08:49 PM
Todays update.

Made the Auto pedal for the brake, cut a auto brake pedal apart and welded the foot plate on over the existing plate.

Changed the exhaust to a rangie pipe, this allows me to put the cross member back on, so i did...
Only catch, its damn close the the wiring that enters the chassis... so exhaust shop will fix that.

Fitted the County handbrake back up, i used the county hand brake, county cable and rangie handbrake mech and drum, its slightly smaller than the county one, but stiff S&%$T. it works.

Wired the Twin thermo's from a V8 falcoon up.... damn things draw 30 amps each...

Started on the Dual batteries

Blew the fuse to the reversing lights as i was a duffer and thought it was the CDL switch wires and grounded one.... DOH...
So still got to find the CDL wires.... That will be fun....

Ditching the Huge county Airfilter as a Ranger only needs a smaller one, so i'll use a smaller one. Easier for me to plumb the Snorkle to it.

Found another coolant leak... water pump.... Grrrrr

Now only 900,000 things to go...

sclarke
10th July 2009, 08:53 PM
Ohh Forgot......

Best part...

Drove it today for the 1st time to see if it got hot and how it ran with an auto in it...

Well, the donor car was a RRC 87 model that had a recent rebuild... and when i got it i found it had stacks of poke and would smoke the tyres in low range very easy....

Today in the county..... it startled me.... even with Twin carbs, it pulls harder than any 3.9 disco or rangie, harder then my 12 month old Mazda BT50.

I smiled..... alot..... and turning out of a round about in High range..... it smoked the tyres.... not Fully Shick mate smoke, but smoke...

and in low range..... off the line it smokes until you hit 3rd.... black tracks out the front on the road to prove it....

Mmmmm I'm excited.... IT LIVES..... only been 2 years...

MacMan
10th July 2009, 09:18 PM
Pics or fail! :p

McDisco
10th July 2009, 09:28 PM
Pics or fail! :p

Yep, pics or fail dude!:D

sclarke
11th July 2009, 06:36 PM
Sooks....
No time for Pix... Work to be done...

The adaptor plate to move it 50mm
https://www.aulro.com/afvb/images/imported/2009/07/1041.jpg

Shifter mounting plate
https://www.aulro.com/afvb/images/imported/2009/07/1042.jpg

All in place and working...
https://www.aulro.com/afvb/images/imported/2009/07/1043.jpg
https://www.aulro.com/afvb/images/imported/2009/07/1044.jpg

There ya go....

Next job.... Front diff and finish the thermo fans and fix the bloody coolant leaks...

Disco_owner
11th July 2009, 06:40 PM
Steve , Just a Suggestion ,I see some rust on passenger and driver footwells , you may want to treat some of that rust and paint it while you have all the Trim out.:cool:

sclarke
11th July 2009, 07:02 PM
Steve , Just a Suggestion ,I see some rust on passenger and driver footwells , you may want to treat some of that rust and paint it while you have all the Trim out.:cool:

OMG RUST.....
its got lots.... thats a job for summer time when its dry...

ITs not fredy flintstone yet..... but during the warmer months i'll rip into it...and the whole fire wall and doors....

lardy
11th July 2009, 07:10 PM
OMG RUST.....
its got lots.... thats a job for summer time when its dry...

ITs not fredy flintstone yet..... but during the warmer months i'll rip into it...and the whole fire wall and doors....

i could get you a quote for a bulkhead when i get mine if you like, i'm doing door skins too, you must be stoked to f@#% that it's a goer, that is a huge undertaking good onya

350RRC
12th July 2009, 09:24 AM
Nice milk crate collection there!

DL

MacMan
12th July 2009, 05:17 PM
So you're not fibbing! :cool:

Looks good!

Rangier Rover
12th July 2009, 06:36 PM
Sooks....
No time for Pix... Work to be done...

The adaptor plate to move it 50mm
https://www.aulro.com/afvb/images/imported/2009/07/1041.jpg

Shifter mounting plate
https://www.aulro.com/afvb/images/imported/2009/07/1042.jpg

All in place and working...
https://www.aulro.com/afvb/images/imported/2009/07/1043.jpg
https://www.aulro.com/afvb/images/imported/2009/07/1044.jpg

There ya go....

Next job.... Front diff and finish the thermo fans and fix the bloody coolant leaks...

Looks a well sorted out job you have done there:) I like it built like a County and drive like a Rangie:cool:

What have you got in mind for a centre console to make it all neat again?:angel:

Disco_owner
12th July 2009, 07:08 PM
Perhaps something like this as an idea Tony :twisted::twisted:

https://www.aulro.com/afvb/

https://www.aulro.com/afvb/

https://www.aulro.com/afvb/


:D:D;)

Rudely copied from Devon4x4 site :(

sclarke
12th July 2009, 07:54 PM
Perhaps something like this as an idea Tony :twisted::twisted:

https://www.aulro.com/afvb/

https://www.aulro.com/afvb/

https://www.aulro.com/afvb/


:D:D;)

Rudely copied from Devon4x4 site :(


I like, but i would like it all to still be infront of the cubby...
i'll measure up what i have in mind and shoot you a pm..
Thanks....

Clarkie

sclarke
12th July 2009, 08:00 PM
Todays effort... as yesterday i was pulling TDI engines out.. Grrrrr

Making it stop as the Disco brake rear end and county Drum rear end master cylinder do not like each other...

Well the problem i struck was after the disc rear end was put in the damn county would not stop.... it was terrible...

This is what i did
Pulled the pedal box out and booster and master cylinder.
Got a solid disc front Disco master cylinder and booster from a MA Vin onwards Disco
Cut and drill and dremel and file and curse and swear and presto....

Seriously...
I found the match up was nearly perfect..
What i found and what i did...
the Disco booster is the same width and its longer than the county one, but the master cylinder is shorter so it all fits.
The disco booster brake pedal plunger is 5-8mm shorter, but LR in its wisdom made a spacer up that when removed is the same length... Tadddaaa..... its just bolted between the booster and bulkhead on the disco, so discard it.
Use it as a template to drill the 2 holes that the bolts pass thru on the Defender/County brake pedal box your about to modify.
https://www.aulro.com/afvb/images/imported/2009/07/1019.jpg

Then you will find the bolts will not have enough clearance to fit a nut as the thread is level with the plate.
I drilled out 3 holes along side it and dremeled it out.
https://www.aulro.com/afvb/images/imported/2009/07/1020.jpg

Then i trial fitted the Disco booster....
Sweet as..

You will notice in the next pic the differances in the County and Disco booster.
https://www.aulro.com/afvb/images/imported/2009/07/1021.jpg

And the pedal to plunger is smaller on the County, so i drilled mine out to about 11mm, that is the size the County one was/is
https://www.aulro.com/afvb/images/imported/2009/07/1022.jpg

Then a Trial fit again
https://www.aulro.com/afvb/images/imported/2009/07/1023.jpg

Then i bolted it all up and popped it in the county.
https://www.aulro.com/afvb/images/imported/2009/07/1024.jpg

Now this is where you will get caught out...
The county master cylinder has 2 different thread sizes. The rear pipe is the same as the Disco, but the front is not... so i ratted the short solid pipe of the rear diff on the donor disco and it was perfect... with some bends....
Ohh and the Vacuum hose will need to be lengthened.

Then i blead the system and took it for a fang....

Yeps its stops..... and locks at 100kmh... time for new disc's and pads and i'll be happy...

Ok, then i had a visitor and we chatted and he bought some gear...
Then i got into fixing the front diff.
The front diff center was flogged out, so as i'm putting a locker in soon, as its still in the RRC PIG i have, i thought a quick swap with a Good front diff i had laying around was quicker... so i unbolted the brake calipers, unbolted the steering and panhard rod, unbolted the trailing arms and then wheeled it out and slid the RRC one i had laying around... it was quicker and less headaches. Gives me time to rebuild the county one properly.
I then bolted up the calipers and presto... better diff center... and no leaking swivels...

Clarkie

Rangier Rover
12th July 2009, 08:06 PM
Perhaps something like this as an idea Tony :twisted::twisted:

http://www.devon4x4.com/components/com_workshop_blog/images/IMG_5311.jpg

http://www.devon4x4.com/components/com_workshop_blog/images/IMG_5313.jpg

http://www.devon4x4.com/components/com_workshop_blog/images/IMG_5314.jpg


:D:D;)

Rudely copied from Devon4x4 site :(

I hope Clarkie is not going to make you polish it as well;) At least being alloy it wont fall apart like rover stuff does:mad: and be light and durable as well.
May get you to make one for the Rangies as well:angel:

sclarke
12th July 2009, 08:44 PM
Ohh yeah...
I'm turfing the AC condensor fans as i'm running a pair of thermos for the radiator.
I'll wire a HP switch into the AC lines so when it gets to a preset high condensor pressure it will bring the Radiator Thermo's on.

That way i have room to cut into the grill for the High mount winch and to place the Oil cooler for the Tranny high up near the bonnet catch..

sclarke
21st July 2009, 08:06 PM
Last 4 days of work.....

Winch rebuilt, fitted to bar and fitted to car
Auto Trans cooler fitted and tranny flushed and filled.
New lenses fitted and one smashed 1 day later.... Grrrrr
Lense protectors fitted, Bearmach ones....mmmm
Bearmach spare wheel swing away carrier fitted
LPG working, but blowing fuse every so often... Grrrr
Air filter box refitted... mmmmm Filted air.....
Power steer reservoir lowered 30mm to miss bonnet...
Container load of parts ordered for spares and replacements.... Water pumps are stupid on price...
Stainless Water tank fitted to back, but still to be adjusted in placement
Diff Breathers fitted.... mmmm nice new hose...
Dual batteries going in.... not as straight forward as i would have liked...
400 spiders kicked out of there home and Cats moved in..

Thats it.....
Till next weekend....

Clarkie

sclarke
24th July 2009, 08:03 PM
Dual batteries fitted tonight.

The isolator i'm using is a 4wd Systems, big baby... 400amp

Ive got both batteries sitting on a 3mm bit of alloy in the battery box.

All toooo Easy...

dullbird
27th July 2009, 10:11 PM
so when can I send the 90 down for its Auto conversion steve?

sclarke
28th July 2009, 03:16 PM
so when can I send the 90 down for its Auto conversion steve?

When you put a V8 in it as well.....

:)

sclarke
28th July 2009, 03:32 PM
Took it for a 300km Fang on saturday night....

Needs a New Dizzy, so ordered a Scorcher Dizzy and coil.

even with the ignition playing up and stuck in traffic for hours 20l/100

I'm half happy...
Bad dose of fuel has not helped... it pings like a pong...

Photo's coming....

Ohh got my Jerry can holder as well..... Happy now... have a 500km range and 250km in the bush...

andrew e
28th July 2009, 10:47 PM
Nice job, i just read this thread from the start and will be doing somthing similar hopefully soon.

Q1 why didnt you go for disco injection? you only need 3 wires to make it run.

Q2 How do you know when the kickdown is adjusted right?

Q3 can you do a pic from under the car showing the exhaust and x members.

Andy

sclarke
29th July 2009, 05:53 AM
Nice job, i just read this thread from the start and will be doing somthing similar hopefully soon.

Q1 why didnt you go for disco injection? you only need 3 wires to make it run.

Q2 How do you know when the kickdown is adjusted right?

Q3 can you do a pic from under the car showing the exhaust and x members.

Andy


To run disco injection.... needed a different tank and pump and lines to and from the engine. Plus i like Carbs, simple and reliable..
if your in the bush and a injection system fails, who can fix it? Carbs.. easy.... i'm a Fan of Simplicity....

Kickdown... i used the linkages from the RRC injection... trial and error... no enough throw the 1st time, too much the 2nd time..., now its about right. might be hanging on that tad too long still....

Exhaust is custom
RRC front pipes and then 6" down from the header they are cut and bent to miss the loom that runs into the chassis, from there its 2" and then at the y its 2 1/2" the rest of the way with one single muffler.

dullbird
29th July 2009, 06:25 PM
When you put a V8 in it as well.....

:)


spoil sport:mad:

sclarke
20th June 2010, 06:34 PM
Time for updates......
After my Outback trip last August/Sept its come home with 9 million faults...
Biggest one.... water leak and oil leaks... Rear main is shagged, so i'll do that one day..
Water leak today i think i found...
More updates on it coming...

Dreamer
10th September 2010, 07:04 PM
Got to hand it to you! Big job! Great effort!