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Thread: Day 1 defender manual to auto conversion

  1. #1
    Join Date
    Nov 2007
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    Townsville Nth Qld
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    Lightbulb Day 1 defender manual to auto conversion

    I have started my conversion on my 97 300 tdi defender ute, converting to Auto. So to assist others a quick how to do.

    thus far i have achieved in the last 8 hours, Remove floor and tunnel cover.

    1. Disconnect batteries ( i have two ) remove starter motor
    2. drop tail shafts , exhaust, and disconnect all wires on transfer case, and transer case shafts
    3. remove handbrake drum, and backing plate place out of way.
    place jacks , remove cross member and gearbox and tranfer case mounts.

    Back inside cab remove transfer case lever and top of gear selector. Box can move free lly backwards with out any hangups.

    next check everything , remove any forgoten breathers ect.

    Support rear of engine, remove all bell housing bolts and slide complete gearbox and tranfer case to the rear and lower to the floor.

    Slide the lot out from underneath the car and remove tranfer from old box and offer up to auto. I changed the seal between the transfer and box as a matter of course, it was not leaking.

    remove clutch plate and flywheel. knock out spigot bush. Fit up auto bell housing, spacer plate , large spacer,flywheel small spacer and do it up tight

    Installaltion of box reversal of removal, Fit up no worries.(point make sure torque convertor does not disengage from pum splines by moving forward.

    I checked that torque was fully inserted and tied it in place with rope and a wooden spacer. At the last moment of fitting cut rope and removed spacer bang in she went no worries.

    refitted mounts and cross member.

    Ok gear selector. I measured and cut out the center acess panel between the seats and fitted the selector their. When connected up to the box it slected gears no worries. Transfer case, you need the top plate out of the auto. I swapped the levers over due to the one i had being seized. Once fitted checked operation by spinning output flanges by hand and selecting hi low et, It seems to work fine.

    re filled transfer case, fitted new cooler lines and spent 3 hours working out how to fit the cooler up. Cracked it at the last moment. So hopefully tomorrow i will fit up kickdown cable, cooler , torque converter bolts, neutral start wiring and run the old girl up.

    I had a mate who was working on his car help to remove and refit box. he helped about 45 mins.

    All the rest can be done eaisily by one person.

    More to follow.

  2. #2
    Join Date
    Jan 1970
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    Bazzle going to move to projects and tutorials so we dont lose this..hope thats cool with you think it will be very helpful to members
    Our Land Rover does not leak oil! it just marks its territory.......




  3. #3
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    No worries

  4. #4
    Join Date
    Aug 2006
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    Kingston, Tassie, OZ.
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    Hi Bazzle, I take it you have all the kickdown cable bracketry off the donor vehicles injector pump? Setting it all up is quite easy, but holler if you need help with anything

    You will be very happy with this conversion, IMO makes a Defender a better drive

    JC
    The Isuzu 110. Solid and as dependable as a rock, coming soon with auto box😊
    The Range Rover L322 4.4.TTDV8 ....probably won't bother with the remap..😈

  5. #5
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    And if you don't, I do



    PM if you want them.
    Attached Images Attached Images

  6. #6
    Join Date
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    Smile Its finished

    Well its finaly finished. Havent driven it far but seems to do what i expected.

    The Saga. First of all . I STUFFED UP, which required me to pull out the box again.. A note to all the flywheel is put in with the ring gear closet to the block. if you put it closest to the transmission. the starter misses by the ring gear width. Dooooh.

    Once that was sorted it went back together fine, and actually started.

    Wiring : two greens off the tranmission switch are reverse wires cut and jion to old plug.
    the other two are neutral start. I just put a relay in the battery box and ran the wires to the switch and the starter. no issues 1/2 hour job.

    Call me rough, the clutch pedal fell of with my grinder, the slave i just cut off and intend to leave the rest in situ.

    The oil cooler sits just in front of the grill. i will put up pictures when i get motivated. Happy to help

  7. #7
    Join Date
    Jan 1970
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    Wheelers Hill, Melbourne
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    That was quick work. Looking forward to the Piccy's.

  8. #8
    Join Date
    Jun 2008
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    Castle Hill, Sydney, NSW
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    Looking forward to the pics as well, thinking about converting Bruce so my wife can drive him more often

  9. #9
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  10. #10
    Join Date
    Jan 1970
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    Old post I know.....

    But where are the pictures? My 130 needs a gearbox, transfer is already out etc. If I dont sell it, I wonder if I should convert it to Auto? Probably not a lot of difference in costs. Gearbox and transfer is already out.....

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