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Thread: Daihatsu diesel conversion problems

  1. #31
    Join Date
    May 2013
    Location
    Elliston SA
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    OK yes I did wonder about the synchros but it appeared identical to the one that came out and the other series 3 synchro I have. I did about 15000 ks with the out of alignment engine, and I`m assuming the synchro was original (I haven`t replaced it before, 15 years ownership) The old synchro was really damaged, the teeth were like knives almost and one had broken off so there was some decent forces happening in there, it looked like a no brainer! I did the selector shaft thing, and as far as I could tell with a torch the splines were engaging fully with the coupling teeth. Funny thing is it doesn`t feel any different at all, perhaps a little less whine (which wasn`t much anyway). I`m considering filing out the detent groove in the shaft as I have a spare selector, but I can`t help thinking I`m fixing a symptom, not the cause, so I`m hesitant....

  2. #32
    Join Date
    May 2013
    Location
    Elliston SA
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    Hi everyone heres another update....I ground out the 3/4 selector shaft detent locator with a burr and drove 10km. Seemed all fixed. Couldn`t help wondering if it had fixed a symptom. Drove 10 ks again this time flat out(!) up a hill, yes you guessed it it popped out, but only once the load reduced a bit. I also noticed (and with hindsight I reckon it was there louder before I realigned the engine) a sort of worn diff whine noise coming from the gearbox before it pops out. Could it be the input shaft teeth working their way out? I`m down to worn input shaft teeth, or too much play in my engine crank bearings.....It`s looking like the input shaft first, a bit more in my league. I`ll just get my wallet.....

  3. #33
    Join Date
    May 2013
    Location
    Elliston SA
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    Rightyo touch wood I think its fixed......seems like the input shaft teeth had just enough wear in it to pop it out of fourth. I put in a new shaft and bearing and crossed my fingers. Even with the high ratio transfer case with my foot flat down labouring uphill I couldn`t make it jump out. It`s still got the ground out selector with transfer case detent plunger though (I wanted everything going my way!!!) It does seem that the HRTC does put a lot of extra stress on the gearbox, its tempting to stay in fourth and grind away but I`m thinking that is a quick way to damage it again. We`ll see how it holds up on a longer trip this month......look out Flinders ranges. Thanks to everyone who had an input, I really appreciated the interest and advice, no doubt it won`t be the last time.....

  4. #34
    Join Date
    May 2013
    Location
    Elliston SA
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    Just one quick P.S. It all seems Ok except it just jumped out of third on the overrun, obvious really the teeth inside the third gear must look similar to the worn input shaft (I didn`t look). Just in case anyone`s reading this with similar problems, consider replacing third also if the teeth are worn (tapered), or the synchro has been really worn (like mine was but not as bad as the fourth gear side).....If you are reading this I`m feeling for you....

  5. #35
    Join Date
    Jan 1970
    Location
    Yea, Victoria, Australia
    Posts
    872
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    Hiya Tim,

    Just skimmed through this post. How is it all behaving now? Is the gearbox going ok now? How does the diesel and high ratio TC match? How is the drive ability?

    I always thought the Daihatsu non turbo 2.8 diesel would have been a good fit to a Series LR. About the same power as a 2.8 Hilux and an engine that can cop a beating. We had one in a Rocky ute and it did heaps of work onroad and offroad and stood upto it without an issue.

    Ended up trading it at about 350,000km and it was the body of the car falling apart not the engine. Sure the injector pump probably needed servicing and the glowplugs and injectors needed replacing but it kept on going and going.

    Richard

  6. #36
    Join Date
    Jan 1970
    Location
    Cessnock NSW
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    I did my own conversion using a Daihatsu N/A 2.8lt in my Series 3 station wagon around 1991, it went very well, yes it used to pop out gear on occasions but I did make my own conversion plate, I do have some Polaroid images of the job somewhere and I still have the full size drawing of the conversion plate somewhere, anyway cheers Dennis
    ps way back in the early 90's (last century) I also had trial fitted a Isuzu diesel (ex Gemini car) into a Suzuki chassis, very neat fit, but I gave the idea away because I didn't think the engineer would pass how I had re-routed the Oil cooler etc,,.

  7. #37
    Join Date
    Mar 2007
    Location
    Tarneit VIC
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    Does daihatsu diesel engine is direct fit or you need to chop the chassis to fit into Series 3?

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