Series 1 - 5 speed gearbox.

Im a bit late to this conversation, but here's what Ive done / am doing in my 86"...

- 300Tdi
- Ashcroft Stumpy Bell-housing
- R380
- LT230 with Disco gearing plus a 50mm extension to the front output flange so that I didn't need to touch the front cross member
- Front prop out of a TD5 Defender (with the extension piece on the LT230, its just the right length)
- Rear prop needs to be shortened a couple of inches (but will still be longer than the shortest 80" shaft from the long nosed diffs)
- Handbrake... Yet to be decided, but there are a few options (An LT230 brake will not fit - too wide and clashes with rear cross member).
i) X-Eng for a Defender - needs lever assembly modifying
ii) X-ENg for a Series - needs an adapter plate making to mount to LT230
iii) Standard S1 Drum brake - needs an adapter plate making to mount to LT230


Jon

Hi Garry.
Im not sure of the differences between the 2 litre bell housing and the 2.286, but what I can tell you is that Im using a Land Rover 90 LT77 gearbox coupled to a 1.222:1 ratio transfer box which is running to 3.54.1 diffs in series axles on 750x16 tyres. I'm using a Tdi which is sat on the original mounts for the 2.286, do the front of the car will remain unchanged. The 90/110/Defender early LT77 fits the earlier 2.2's, the only change being relocation of a couple of studs. To use this box, I've removed both middle x members, and re located the original gearbox x member to suit the LT 77. If its sighted in the right place, the only tin work internally that will need changing is the gearbox tunnel. I've removed the Hi/Lo/CDL selector and am going to try and make up some linkage so as to retain red and yellow levers. I've managed to retain the Series Handbrake. If you need some pics, look in Projects and Tutorials for the thread 'SWMBO's Ser 2 Tdi the beginning'.... It'll b a few pages down as I've not done anything to it since the arrival of the 101!!! :)

Sitec

The difference between the S1 and 2.283 bell is explained in post 2 of this thread. Basically the 200Tdi bell is the same as the 2.283 which has a larger internal diameter, so you need either the lip of the bell machined off or the S1 flywheel housing machined out and the studs repositioned for the larger diameter and position.

You would also have to use a SIII 6cyl flywheel so you can fit the Defender pressure plate,

Just to clarify, if I ever did this mod the gearbox would still be mated to the 2 litre petrol engine.

I like the idea of the stumpy R380 having previously owned a Disco 1 with the LT77 I just do not like the gear layout - 1st is too close to reverse.

Thanks for all the advice - great stuff.

Garry

The Nissan cabstar conversion from Marks has a very long bell housing/adaptor plate and so it pushes the holden six a long way forward in the 88" vehicles so in an 80" coupled to the four cylinder it would still be very compact, but no doubt doable. I have a 2A 88 that has the cabstar box and I have pulled the holden six out and am currently rebuilding a starfire four to fit into it. It should work out well and all the engine mounts, bell housing bolt pattern etc are as per the six cylinder engine. I did drive the vehicle on a permit with the six in it and found the cabstar box very good, but as Arthur stated it has a very low first. It would probably work well in a four speed version with 3.54 diffs. It's a shame Marks didn't also do a conversion for the cabstar box mated to a Land Rover 2 1/4 motor.
Overall though a series box and series motor with a roamerdrive would be a good combination unless you have an application for it where you are going to totally murder the gearbox.
My daily driver is a 88" series 3 with a holden 186, 3.54 diffs, a roamerdrive and an almost buggered gearbox I fitted temporarily 13-14 years ago and it is still hanging in there.


Cheers, Mick.

Quote:

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Originally Posted by garrycol

Just to clarify, if I ever did this mod the gearbox would still be mated to the 2 litre petrol engine.

I like the idea of the stumpy R380 having previously owned a Disco 1 with the LT77 I just do not like the gear layout - 1st is too close to reverse.

Thanks for all the advice - great stuff.

Garry

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I have heard of people having that problem but I have no problem with the LT77 in our Disco. I quite like the box even though the synchro is not working well.
Perhaps the springs in yours that control the lever throw were out of whack.
When they are good there is a pronounced exra pressure needed for reverse.
I have a Defender 200tdi and LT77 I am going to fit into a S1 88" one day:D

Just following up on my promise

This is a standard 6cyl SIIa flywheel housing which is essentially the same as a S1 housing

https://www.aulro.com/afvb/images/im...15/01/1240.jpg

And connected to a gearbox bell

https://www.aulro.com/afvb/images/im...15/01/1241.jpg

The following are all a SIIa 6cyl flywheel housing modified for an Ashcroft stumpy R380. Note alloy build up for repositioned studs.

https://www.aulro.com/afvb/images/im...15/01/1242.jpg

internal lip machined to accept lip on stumpy (4 cyl gearbox bell)

https://www.aulro.com/afvb/images/im...15/01/1243.jpg

Connected to Ashcroft bellhousing

https://www.aulro.com/afvb/images/im...15/01/1244.jpg

Note repositioned starter dog cover

https://www.aulro.com/afvb/images/im...15/01/1245.jpg

https://www.aulro.com/afvb/images/im...15/01/1246.jpg

Pretty impressive stuff Diana. Just goes to show that where there's a will, there's a way!

Quote:

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Originally Posted by Sitec

I've removed the Hi/Lo/CDL selector and am going to try and make up some linkage so as to retain red and yellow levers. :)

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I have just finished a similar project for my Series IIa. LT77 & LT230. Same levers and same operation as original. Except that you have to pull up on the yellow knob to disengage diff lock. It does not pop-up when pulling the red lever;). Took me many prototyping but it is finally working :D All the floorboards are still out so if you'd like a picture, let me know.

Quote:

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Originally Posted by AV8R

I have just finished a similar project for my Series IIa. LT77 & LT230. Same levers and same operation as original. Except that you have to pull up on the yellow knob to disengage diff lock. It does not pop-up when pulling the red lever;). Took me many prototyping but it is finally working :D All the floorboards are still out so if you'd like a picture, let me know.

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Pictures and a sketch would be excellent I possible.