Fitting 300tdi into v8 disco1, and switching to 5 speed and toyota axles

Thought id update.

Ive got the truck running and driving down the road, and quite happy with it generally speaking. I filled up my first tank and am achieving 19-20 mpg with a good mix of 4x4 and hwy driving.

I now have 285/75/16 tires, So am quite impressed with the mpg considering the axle ratio isnt a good match for the tires.

The engine seems to have been signifiicantly undertuned when it was shipped, it must be put in low range to start on a hill, and Ive noticed there is no smoke when lugging the engine in a taller gear. I would like to address that at some point.

More pressingly, I cannot seem to get around a leak at my r380 output shaft seal, it also appears the Tcase seal is leaking too. i installed new seals when I mated the units on the bench.

within an hr or so of running, the gearbox seal was destroyed and leaking.

tore it back apart, replaced seal again.

now 500 miles later, I see it is leaking again. I am baffled as to why this will not stop.

I heard the mainshaft collar is replaceable, so I will try that next i suppose. I also read some place that the collar should be removed when installing the seal or the spring gator will fall off?

It looks like a pretty unique puller tool to remove that collar, It amazes me that it would need removed to change a seal.

another question, is it possible to replace these two seals accessing through the rear of the transfer case after removing the intermediate gear?

To stop my tc input stall leaking I had to make a sandwich seal which seated the seal at the right depth as the tc is bolted up.
I had endless problems before that. It's been dry since.

so yours was leaking becuse it wasnt seated to the right depth?

so now youve essentially added a third seal between the two existing?

Quote:

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Originally Posted by moneypit_k5

so yours was leaking becuse it wasnt seated to the right depth?

so now youve essentially added a third seal between the two existing?

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I think it was also getting crooked and or damaged in the way in. Now the seal is placed on the shaft and can't be damaged during case installation.

You need to get boost and egt gauges for tuning. Smoke isn't a reliable indicator of high egt and small engines run at higher load than big ones.

Check the breathers for both the gearbox and the transfer, the cases maybe building up pressure inside of them.

The banjo bolt holding the breather tube down, has a hole on the end of it that can rust over, blocking it off.
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Thanks arthur, I had considered that as well, but no such luck. Im going to tear it down and replace collar and the seal again.


So Ive discovered a strange condition where my rear axle is not centered to the frame. My drivers tire (285/75/16) is rubbing the top of the coil tower on the LH side, and has 3+ inches of space on the RH side. Thus my axle is about 1.5" out of alignment.

I cant see any bent parts, no indications the truck was ever in an accident. I dont see any way to adjust it, the 2" lift should have no effect on this centering geometry.

What on earth is going on here? did LR really do that bad of a job centering the axle?

I am going to be installing the Toyota axles next week, and will move the mounts accordingly to center it, but Id like to get some other opinions before I change the mount locations.

What's the centering device for the rear axle? You're using LC axles and ??? centring, original a frame or adapted panhard or watts link.

Panhard is susceptible to lift but +2" shouldn't move that far but it also depends on other geometry arrangements. Watts and A-frame won't walk so it could only be adaption of the system onto the new axle that's been mis aligned.

The upper A frame mounts can be shuffled sideways on the chassis for centreing. But not that amount.

This is a disco 1 so There is no panhard, just an "a frame"link.

The oem rover axle is not aligned. I have not put the toy parts in, but am thinking ill fix the alignment by moving the brackets on the new axle.

Unless i missing something here, this truck had to have come from the factory like this.

Any chance of some photo's of that misalignment before you pull it apart?