Thread: Full 300tdi Disco running gear into 2a 109 ute

Perhaps the most efficient way to tackle this is to create a list of issues/tasks.
I'll kick things off:

New engine/gearbox mounts
New suspension mounting points, including new outriggers (to use factory disco trailing arms)
New propshafts of correct length (as disco is 100in wheelbase)
Flares for the wider wheel-track
Fuel return lines to the tanks
Panhard rod mount on chassis

Id like to keep the series look front-end if i can, which may be do-able as due to the 9in longer wheelbase of the 2a over the disco, I could mount everything just a little further back and maybe even keep the factory disco rear propshaft...... provided that the length of the radiator, 300tdi engine, gearbox and transfer case can fit between the series grill and the chassis crossmember behind the transfer case..............?

Would it not be easier to mount the the 2a body strait on to the disco chassis?
There would be a lot less fabrication involved

I see your case, a Disco chassis would have ADR's applying, so no go. An early RRC chassis would be my choice for a donor chassis if you did it the easier way (a 100 inch special). Otherwise just enjoy picking every bracket off the Disco chassis and welding it on to the series chassis.

Anything is possible - somewhere on this site is a S3 (I think) which has had the 300tdi fitted with all of the upgraded drive-train. I am pretty sure that in the UK you can buy coiler chassis for series cars, so there is probably heaps of info on the web.

My advice is to contact your licencing authority and tell them what you want to do and ask for their advice - I always find that "asking for advice" is the best way to approach people in authority In WA they encourage anyone to do that, which seems to be a sensible approach before spending any money on a project.

Good luck, keep us posted on how you get on,

Cheers Charlie

Yeah, I'm not interested in using another chassis, it's gotta be Bruce's chassis and body. I've got no problem with taking all the brackets off the disco, that's what I had in mind. My first step after these holidays will be to go and have a chat to an engineer in sydney and see what the go is.

I'll have a search tonight to see if I can find that series 3 with the full running gear conversion, that'd be a great starting point!

I found mention of this conversion on a series three, but couldn't find a thread on it. Can anyone else find it?

i don't really know too much about a full conversion especially with the 300tdi running gear

but one thing i do know is you will have to move the injector pump side engine mount on the chassis(i'd say offside but i'm not sure if you lot drive on the wrong side of the road)

you'll have an interesting time connecting up steering linkages from what i understand if you use the disco axles (not to mention having to weld on spring perches in the correct place), you'll also need custom length props and the disco gearbox has a "veeerrry" long bellhousing which will probably put the gearstick under your elbow

now just to clarify things i've only owned landrovers for two years but i've been modifying my little 88" from the day i bought it, that is now fitted with a 200tdi which bolts in on the original series box and straight onto the original mounts..

i've also fitted 3.54 diffs (not axles) from an early disco/range rover as they're 10 spline and stuck an overdrive on the back of the box, 11" backplates (single leading shoe) off a salisbury rear axle onto my front axle, parabolic springs and 1 ton shocks all round...

i think it drives and stops brilliantly but i've not driven another to give it a fair comparison ...

i'm now in the process of rebuilding a 1965 109 utility, this one is getting a 200tdi engine that will be fitted with a 300tdi exhaust manifold/turbo (to clear the chassis rail) and i'll be changing the diffs again, 4.3:1 ratio this time to see if i prefer them (would really like 3.9:1 tho) and another overdrive ...

both of these conversions will return somewhere in excess of 30miles to the gallon as long as i'm not thrashing the motor, my 88" easily sits on the motorway at 70mph even on Deestone Extragrips (7.50x16) and i think i've touched 90mph when on the same size tyres but road orientated tread pattern and freewheel hubs disengaged (took a long downhill run ) i sat comfortably on the m/way the other day towing a dolly with a ford escort on it at 55-60mph (legal towing speed here) dropped the escort at Manchester then took the scenic route back (damn stupid satnav)so i didn't hang about, i reckon we did just about 200 miles on no more than 3/4 of an underseat tank of fuel (i also had a slight fuel leak from my injectors where i'd had to dismantle it all to get the water out of my bores the day before, i sank it in the river)...

i very much doubt it's worth the effort of dropping in the disco or even a defender gearbox due to the amount of messing about with crossmembers, prop shafts and the trans brake even with 5 gears i doubt you'll match my top ratio in my 88"

oh and yes i do offroad this 88" as well as use it as my daily driver, 2 years on a tired S3 gearbox and it's not gone bang yet, i've also not snapped a halfshaft but that could be the 3.54s protecting them

p.s.
300tdi axles use 24 spline diffs so you won't even have the cheap ratio experiments that i can do, i'm not sure if you'd be able to fit early 200 halfshafts and 10 spline diff

You won't be able to get the 300Tdi engine and transmission into the series chassis and still retain the front body profile without removing the cross member behind the gearbox. You will then have to do some major mods to the firewall and tunnet cover and may then find that the Disco gearstick comes up through the middle seatbox.

The power steering box, will want to sit where Bruce's front cross member currently sits (think stage 1) and where will you be fitting the radiator?

BTW: the Rover 4.3 and 3.9 ratio diffs mentioned by NiteMare are possibilities but are getting as rare as hens teeth in Australia, and the Rover car enthusiasts who may still have them are very unwilling to part with them for Land Rovers. You also lose the 1st gear crawler ratios if you up the diff ratio. Remember Australia's rocky terrain is very unforgiving on Rover diffs and Series axles, particularly on a 109.