Got my D2!!

[Shamo]

Hey all,

On Monday i finally recieved my D2. It has been a few weeks of stuffing around with trucking companies and dust storms etc. but i finally got the thing. Its a 1999 TD5 Disco 2 7 Seat with SLS and ACE (manual). It has a few extra's at the moment including;

2 inch lift
Safari Snorkel
245/75 Mickey T atz
ARB bar
IPF lights
Dual batteries with inverter

Some pics;

When i got it (it was ontop of the truck on the way home and apparently it was actually raining mud haha)
https://www.aulro.com/afvb/images/imported/2010/11/1001.jpg

https://www.aulro.com/afvb/images/imported/2010/07/1237.jpg

https://www.aulro.com/afvb/images/imported/2010/11/1003.jpg

https://www.aulro.com/afvb/images/imported/2010/11/1005.jpg

I bought the car at a fairly good price because it has a few problems with, but they should all be sorted soon. I changed all the oils over the past few days (engine, gearbox, tranfer, and diffs) but when i changed the front diff i was confronted with some rather large chunks of metal... So we decided to pull the front diff centre out to investigate...

After alot of struggle trying to get the steak nuts off the ends of the hub (they are possibly the most incredibly tight nuts i've ever encountered) we pulled out the axles and then the diff centre to find that all the planetry gears are stuffed but the crown and pinion are still fine.

So after alot of deliberation and calling around i finally decided a locker would be the best way to go about fixing this problem! So i recieve my ARB air locker next Thurday and will hopefully be in by the weekend!

Dan having a go

https://www.aulro.com/afvb/images/imported/2009/09/50.jpg

https://www.aulro.com/afvb/images/imported/2009/09/51.jpg

Broke two 1/2 inch drives trying to get the bloody steak nut off

https://www.aulro.com/afvb/images/imported/2009/09/52.jpg

Diff centre out = planetry gear stuffed
https://www.aulro.com/afvb/images/imported/2010/11/1006.jpg

The diff was actually already a naturally aspirated locker :P as you can see that rod has snapped through the middle and crunched everything around it and just locked itself, luckily the pinion and crown wheels are still in good condition.
https://www.aulro.com/afvb/images/imported/2009/09/53.jpg

https://www.aulro.com/afvb/images/imported/2010/11/1007.jpg

Shamo

[Shamo]

Also forgot to mention that i'm going to fit the rear diff centre into the front and run the locker in the rear instead of the front.

Also the list for what else is happening to it;

Putting in/on from my D1;

Uniden UHF,
Warn 9000 pound winch
Maxxis Bighorns 245/75

and in the near future,

TJM bar to fit my winch
Some lightforce xgt's
33" federal mt's
Fridge

Shamo

[cal415]

Nice work, i broke 2 breaker bars removing the axles nuts on my old d2 as well,, we tried heaps of things including a huge rattle gun... in the end we cut the nut off and replaced it with a new one.

That diff damage is ugly!! bloody amazing the CWP is ok.... make sure you check it right over for nicks etc as anything like that could weaking it or cause some noise.

[waz]

What a great looking truck! ...except for the front diff...

Will you need a bigger lift to fit the 33s?

W

[Hendrik]

Your right Cal, we took that diff out just in time, the CWP is still good, gave it a good look over. A few more kays with the diff like that, and the CWP would have gone I reckon. But it goes to show the importance of the CDL and Low range in offroad situations. The transfer case will not go into low range, still trying to fix that. So the previous owner, must have done quite a bit of offroad work in high range and with no CDL.
With the traction control working over time, it must have put a lot of strain on the diff, so it eventually gave up. I would recommend the CDL as the first modification for a d2 as it is just so important.
As far as I know (don't quote me on that) the axles and CV's in D2's are stronger than D1 and RRC axles due to the addition of traction control, but if only they made the hemisphere stronger.
But I guess it gives him a good excuse to put the ARB in.

Waz, you can run 33's with only a 2 inch lift without cutting the guards, but you need to fit rock sliders as they rub on the plastic sill covers.

So I guess Shamo now you can help me pull out my front diff as it has been humming away for ages, could knock up some sliders at the same time, see how we go...

[Shamo]

Thanks for the comments guys, does anyone know weather or not i have to change the joints where the tail shafts attach to the diff centres? or will they be the same front and back?

Also does anyone know how much a rebuild of a transfer case would cost? its looking like i may need one...

Shamo

[Outlaw]

Congratulations on the purchase Shamo... guess she'll be ready to play at Coffs :D

[Shamo]

Congratulations on the purchase Shamo... guess she'll be ready to play at Coffs :D

Thanks mate, i bloody hope it will be! wont be ready for the meeting tmrw night though sadly, i'm marooned in Toowoomba at the moment haha.

Shamo

[**Discovery300Tdi**]

Well done shamo, great lookin rig. Amazing what a wash could do!!!
Good luck with everything. :thumbsup:

[disco_thrasher]

Thanks for the comments guys, does anyone know weather or not i have to change the joints where the tail shafts attach to the diff centres? or will they be the same front and back?

Also does anyone know how much a rebuild of a transfer case would cost? its looking like i may need one...

Shamo
What area are you in

[long stroke]

Looking awesome:cool:
Can't wait until you get your 33's on they will look sweet!!

here's a pic of Matmans d2 with 33'' federals under the guards:)

https://www.aulro.com/afvb/images/imported/2009/10/1718.jpg

CHEERS TIM.

[Shamo]

What area are you in

I'm in Brisbane and Toowoomba mate (in queensland).

Shamo

[Shamo]

Looking awesome:cool:
Can't wait until you get your 33's on they will look sweet!!

here's a pic of Matmans d2 with 33'' federals under the guards:)

https://www.aulro.com/afvb/images/imported/2009/10/1718.jpg

CHEERS TIM.

That looks good! I love the 33s under them, my mates keep trying to talk me into the 265/75 but i dont think i could when its so easy to fit the 33's :D

Shamo

[Redback]

Are you going to get a chip upgrade for it or 411 ratios:confused:

The reason I ask is, fitting 33s will drag a lot of power from it and being a manual you will notice it a lot, especially on take off and towing.

Baz.

[Shamo]

Are you going to get a chip upgrade for it or 411 ratios:confused:

The reason I ask is, fitting 33s will drag a lot of power from it and being a manual you will notice it a lot, especially on take off and towing.

Baz.

Nah mate, might chip it but i wont be towing anything and its not really my sports car, i know how much they do die in the ass when you put on big tyres but ah well, im hoping to have a road set also for it.

Shamo

[Redback]

Nah mate, might chip it but i wont be towing anything and its not really my sports car, i know how much they do die in the ass when you put on big tyres but ah well, im hoping to have a road set also for it.

Shamo

OK well in that case, if you do chip it, don't chip the ECU you have in the car, buy a D2a flashable ECU from LR, in your case Part No NNN500020(BELIEVE OR NOT THEY ARE CHEAP) and have it re-mapped by Tombie, it will work out around the same price and if you have a Nanocom you do it yourself:D

Baz.

[Shamo]

OK well in that case, if you do chip it, don't chip the ECU you have in the car, buy a D2a flashable ECU from LR, in your case Part No NNN500020(BELIEVE OR NOT THEY ARE CHEAP) and have it re-mapped by Tombie, it will work out around the same price and if you have a Nanocom you do it yourself:D

Baz.

Awesome that sounds like a good idea, is that cheaper than going 411s? or is that what you meant when you said it'll work out at about the same price?

Shamo

[Redback]

Awesome that sounds like a good idea, is that cheaper than going 411s? or is that what you meant when you said it'll work out at about the same price?

Shamo

Yes cheaper than the 4.11s

The flashable ECU upgrade and remap will be around $1100 and the 4.11s are around the $2000 F & R, if you chip your current ECU it's around $900 to $1400.

Baz.

[Hendrik]

Yes cheaper than the 4.11s

The flashable ECU upgrade and remap will be around $1100 and the 4.11s are around the $2000 F & R, if you chip your current ECU it's around $900 to $1400.

Baz.

The quote you got for the 4.11's is that installed? I've seen them for $600, but that is not installed. I've given 4.11's a lot of thought as the gearing in a manual does get annoying, and you do notice it more offroad with 32's. Personally I think 4.11's will be more beneficial than a chip, eventhough it might be more expensive. I have found that I do more hill climbs in 1st gear low now, where I used to be able to do them in 2nd gear low with the standard size tyres. 2nd just doesn't seam to have the torgue it used to, due to the change in gearing, and I would love to have that back.

[Redback]

The quote you got for the 4.11's is that installed? I've seen them for $600, but that is not installed. I've given 4.11's a lot of thought as the gearing in a manual does get annoying, and you do notice it more offroad with 32's. Personally I think 4.11's will be more beneficial than a chip, eventhough it might be more expensive. I have found that I do more hill climbs in 1st gear low now, where I used to be able to do them in 2nd gear low with the standard size tyres. 2nd just doesn't seam to have the torgue it used to, due to the change in gearing, and I would love to have that back.

I have also found that 32s do affect the crawling ability of my manual off road, but also the B Davis chip has affected it too, it has altered the ECUs ability to change the throttle responce from hard to soft when in low range, this is one reason why I'm going to the later ECU to fix that problem another problem with the BD Chip is it will surge for a milli second when in low range but it does it suddenly, first time it happened it scared the crap out of me, it just took off:eek:

When I asked Bruce about it he said yes it does that, but I haven't been able to fix it:eek:

One of the quotes I got for 4.11s was from 4x4inteligence at $!060ea + installation, yes I have seen them cheaper as well, I was just giving an average price, one thing though, if you do fit 4.11s to your D2, you will lose cruise control according to slunnie.

Baz.

[Hendrik]

Thanks for that Baz
I also have a flashable ecu now, just have to program it in and will use the non-flashable one as a spare. I will leave the chip for later on though, as I'll first see how it goes with the new ecu, apparently it is a lot smoother in low range and you do get a bit more torque down low as well.
Yes I have read about the cruise control issue as well, might confirm that with MickG as he is in our club and has 4.11's on his D2. I guess the other (more expensive) option is a defender transfer case, have heard of a few people do the change over into a d2 and it fixed the gearing issues in high range. I am not too sure about low range though.

[Shamo]

I get my locker tmrw and its being installed in the front diff centre at the moment. I was going to put it in the rear but think that the changing over of the flanges from the rear diff to the front one may cause me some hassles? is it a simple change over or is it more of a job than i expect?

Also, would it be better to run a front locker anyway? i have heard way too many pro's and cons of front vs rear and still cant make up my mind. For the moment it will be on the 245/75 tyres because my pocket is a fair bit lighter after the locker and probably cant afford the 33s for a little while (not till early next year atleast)

Shamo

[Redback]

I get my locker tmrw and its being installed in the front diff centre at the moment. I was going to put it in the rear but think that the changing over of the flanges from the rear diff to the front one may cause me some hassles? is it a simple change over or is it more of a job than i expect?

Also, would it be better to run a front locker anyway? i have heard way too many pro's and cons of front vs rear and still cant make up my mind. For the moment it will be on the 245/75 tyres because my pocket is a fair bit lighter after the locker and probably cant afford the 33s for a little while (not till early next year atleast)

Shamo

Initially you shouldn't need to change the rear roto flex to fit the locker, as long as you don't shock load it hard and often, but it should be done sooner rather than later, never heard of changing rear to front, early D1 flange and uni is the go when fitting a rear locker, front doesn't need changing.

Second I'd go the rear locker first.

Third do you have upgraded axles, because you will need them, especially if you decide to run a front locker first and 33s, also I'd be looking at heavy duty CVs as well, a front locker on it's own and 33s, you will break an axle or a CV or both.

Baz.

[Shamo]

Initially you shouldn't need to change the rear roto flex to fit the locker, as long as you don't shock load it hard and often, but it should be done sooner rather than later, never heard of changing rear to front, early D1 flange and uni is the go when fitting a rear locker, front doesn't need changing.

Second I'd go the rear locker first.

Third do you have upgraded axles, because you will need them, especially if you decide to run a front locker first and 33s, also I'd be looking at heavy duty CVs as well, a front locker on it's own and 33s, you will break an axle or a CV or both.

Baz.

Thanks for the comment mate but im not sure if you understood what i meant, because i had the front diff out because of the damage it did in the planetry gears i got the locker fitted in the front diff and today i changed it over so it was in the rear rather than in the front, i had to change the flanges because the rear one is different to the front because they have the donut in the rear and a different fitting, it wasnt too much trouble to change over and she's all done now! wiring up the compressor tmrw.

What axles do you suggest i should invest in?

Shamo

[Redback]

Thanks for the comment mate but im not sure if you understood what i meant, because i had the front diff out because of the damage it did in the planetry gears i got the locker fitted in the front diff and today i changed it over so it was in the rear rather than in the front, i had to change the flanges because the rear one is different to the front because they have the donut in the rear and a different fitting, it wasnt too much trouble to change over and she's all done now! wiring up the compressor tmrw.

What axles do you suggest i should invest in?

Shamo

Oh OK I got it now:bangin:

Longfields seem to be popular, Maxi axles are still available too, you can get upgraded CVs and axles from Rovacraft, they are a set, last I heard they were $1850 for the set here or 600 pounds + shipping from the UK, they import them from Ashcrofts in the UK.

Longfield Super Axles (http://www.longfieldsuperaxles.com/)

Ashcroft Transmissions (http://www.ashcroft-transmissions.co.uk/part_72.html)

Baz.

[Shamo]

Oh OK I got it now:bangin:

Longfields seem to be popular, Maxi axles are still available too, you can get upgraded CVs and axles from Rovacraft, they are a set, last I heard they were $1850 for the set here or 600 pounds + shipping from the UK, they import them from Ashcrofts in the UK.

Longfield Super Axles (http://www.longfieldsuperaxles.com/)

Ashcroft Transmissions (http://www.ashcroft-transmissions.co.uk/part_72.html)

Baz.

Thanks for that mate, geez this thing is going to be my big old endless money pit isnt it haha.

Got the locker in today and all wired/airlined up, its awesome, love the sounds it makes hehe. Just need the wheels now! the rims are at the shop getting my horns put on them from my d1 set. Should be all good to go monday!
I just need to sort out the tranfer case now, it wont go into low range :confused: it sort of engages but slips out... i think, either that or it sort of engages into neutral and then slips out, i havnt had a chance to have another look at it to sort it out because its been immobile obviously. I'll give it a try monday and find out what the hell its doing... Any ideas?

Shamo

[long stroke]

Probably due to a lack of use (low range) give the linkages a spray and just play around with it until it go's in, you might have to reverse and go forward etc while trying to push it in, once it is in give it a good workout;)

Looking gooood:cool:

TIM.

[Redback]

Thanks for that mate, geez this thing is going to be my big old endless money pit isnt it haha.

Got the locker in today and all wired/airlined up, its awesome, love the sounds it makes hehe. Just need the wheels now! the rims are at the shop getting my horns put on them from my d1 set. Should be all good to go monday!
I just need to sort out the tranfer case now, it wont go into low range :confused: it sort of engages but slips out... i think, either that or it sort of engages into neutral and then slips out, i havnt had a chance to have another look at it to sort it out because its been immobile obviously. I'll give it a try monday and find out what the hell its doing... Any ideas?

Shamo

Sounds like it could be in the transfer case, not the same as the D1 Long Stroke, the D2 is cable operated, you could try adjusting the cable on the low range lever, it might work.

Put a post in technical, you may get a more accurate answer.

Baz.

[Shamo]

Thought it may be time to update this thread, i ended up getting the transfer case fixed, i took it out and took it to Techno Brittish and they just pulled it apart for me and found nothing and put it back together and it worked, so just put it down to lack of use (or no use) in the past haha.

I am currently in the middle of doing an SLS to coil conversion in the car (because i got a hole in one of the bags and i found a deal that was cheaper to put in coils than replace the bag, and the front end is also sagged pretty much down to standard), i am just waiting on my lift at the moment so i have been fiddling around with a couple of things on the car.

Did this last night... http://www.aulro.com/afvb/projects-tutorials/99247-discovery-td5-exhaust-modification.html#post1188910

I am also in the middle of building some sliders for the rig and a rear bar will follow in the future when i have the funds as i have smashed the hell out of my current rear bar :D

Also getting some 33s with the lift and will be fitting them :) they are silverstone mt117 sports. I plan to run them on black sunnies and run my standard size all terrains (that i have in the shed) on the alloys so i don't have to run the big and noisey tyres all the time. But at the moment i will have to run the muddies on the alloys, will give me a chance at seeing how bad they really are with the gearing :)

I shal post up some photo's when i've finished the lift and tyres!

Shamo

[disco_thrasher]

yeah not wrong there a very good deal ,as long as they gonna be used as i would want them and i know you will :D

the tyres are noisey but very good wearing and not bad on the black top as for the gearing before i had mine changed it was not to bad
your Disco is now gonna become a rig:D
see ya thursday around mid day ish call me for adress in Gilston by nerang

cheers kelvin

[Shamo]

yeah not wrong there a very good deal ,as long as they gonna be used as i would want them and i know you will :D

the tyres are noisey but very good wearing and not bad on the black top as for the gearing before i had mine changed it was not to bad
your Disco is now gonna become a rig:D
see ya thursday around mid day ish call me for adress in Gilston by nerang

cheers kelvin

Bloody oath i'll use the suspension well! hopefully i want be smashing my rear bar as much now because my air bags won't be letting themselves down when i'm trying to get up a track... haha

can't afford to change my gearing, uni student wage :angel: so i'll just deal with it!

Will see you there! I'll give you a call tmrw night anyway to confirm everything.

Cheers,
Shamo

[Shamo]

New pics up here!

http://www.aulro.com/afvb/gclro-members-rides/99650-ive-created-monster-shamos-d2.html#post1193305

Shamo

[fatman]

New pics up here!

http://www.aulro.com/afvb/gclro-members-rides/99650-ive-created-monster-shamos-d2.html#post1193305

Shamo

Very nice.
Is this a true 2" lift?
I am looking forward mounting 255/85 16's with a similar lift..

[Shamo]

Hey mat not sure what you mean by "true"? If you mean it's not fully 2 inches lifted then yes it is, it may look less in the pics because the tyres are so big I'm the guards, and also I dontthink the camera gives it much justice as it is actually really high in person, I am a really tall guy and I have found myself now having to climb a little bit to get into it haha.

On the other hand if you mean that it is actually more than 2 inch then no it's not it's just your standard 2 inches of lift on heavy duty coils (alot less sagging occurs)

Cheers,
Shamo

[fatman]

Thanks for the reply mate!
I meant it looked more than 2" to me,more than enough clearance for such a tyre size.
Did you observe any major rubbing anywhere? (minor's not a problem for the dremel ;))
As i see it the modification sequence goes like this,first Shamo's way and next Slunnie's way or Disco-trasher's way :BigThumb:

[that_kid]

shamo you know those tires would look sooooo much better on my car!!

let me know when u get sick of the gearing!

being a uni student is a cop out! i think what you mean is a lazy uni student! im a uni student and im geared down!

never been a big fan of putting the switches there but i spose for those of us that cant afford a HSE (aka us uni students) it makes use of the otherwise blank plastic. i spose the third hole can symbolise your optimism haha!

looking good man! just have to get out for a wheel!

[Shamo]

Thanks for the reply mate!
I meant it looked more than 2" to me,more than enough clearance for such a tyre size.
Did you observe any major rubbing anywhere? (minor's not a problem for the dremel ;))
As i see it the modification sequence goes like this,first Shamo's way and next Slunnie's way or Disco-trasher's way :BigThumb:

That's alright mate, i took it for a quick flex on my flex piles and didnt hear any rubbing (i didn't get out cause it was midnight and couldnt see much) and when i got back in the shed there was only a little bit on the rear of the front wheel arch, nothing to worry about :D The piles are the extreme of how far they will flex too (only just got on with the rear locker in and im pretty sure the wheels were off the ground diagonally opposite so its pretty flexed out)

Keep us posted with what you do!

Shamo


shamo you know those tires would look sooooo much better on my car!!

let me know when u get sick of the gearing!

being a uni student is a cop out! i think what you mean is a lazy uni student! im a uni student and im geared down!

never been a big fan of putting the switches there but i spose for those of us that cant afford a HSE (aka us uni students) it makes use of the otherwise blank plastic. i spose the third hole can symbolise your optimism haha!

looking good man! just have to get out for a wheel!

Haha yeah but your not doing a Mechanical engineering degree are you, i actually have to study a bit when i get home! :wasntme:

Come to cruiser you pansy, you know you want to!

Shamo