another S3 diesel transplant question defender into S3

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Originally Posted by Hardchina

This would be perfect with the high speed transfer case - good high ratio (2900 rpm in 4th, 2200? in 5th) and still stock low range :cool:

How much was the kit?

Cheers

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They are $600 plus freight. Only problem is you can't use it with the High Speed Transfer Case conversion as the gear on the gearbox output shaft is changed. Knowing Ashcroft though, they could probably provide a gear to suit.

All good ideas Travis and I am still crunching the numbers (even though I don't have the money :D).

In my case I have the following to consider (and perhaps most others will need to consider them as well):
1. R380 Stumpy gearbox A$1575 (not sure if this is the right one)
2. Series 5 speed kit A$600
3.High ratio transfer kit A$425 + $125 surcharge = $650
Sub Total $2825
Plus freight, etc.

Your idea of the transfer box kit is a good one and I have considered it myself, however, compared to an overdrive it has the following disadvantages:
1. I think the transfer box has to be machined - please correct me if I am wrong.
2. If I purchase from Ashcroft the box needs to be sent to the UK, or pay a surcharge and do the work here.
3. Once the modifications are done to the car they really have to stay with the car - an overdrive can be removed and kept or swapped between the fleet.

Decisions! Decisions!

Cheers Charlie

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Originally Posted by jakeslouw

Transplant the TDi with transmission straight into the S3. Then take a set of early Deefer axles, cut off the coil seats and weld on leaf spring seats (use square tube steel with a semi-circle cut for the axle tube profile, drill a hole to locate the leaf spring peg).
At the same time (oh sacrilege...) go Spring Over Axle with parabolics.

So, you get 3.54 diff ratios, an extra 4-6 inches clearance, highway cruising speed, low fuel consumption, no problems with axle strength.....


Jeez, I can't seem to find the negative aspects......

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Just some of the negative aspects are:

You have to weld the rear shock absorber mounts

Manufacture or move the engine mounts on the chassis

Manufacture or move the gearbox mounts on the chassis

The whole driveline is longer so you need to either move it all back or forward. This means either modifying the propshafts or moving the radiator support forward

Build a new gearbox tunnel to accomodate the new gearstick and transfer stick

Modify the gearstick to move it back or forward so it's reachable in the cab

Modify the handbrake system and lever to fit

Quote:

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Originally Posted by chazza

All good ideas Travis and I am still crunching the numbers (even though I don't have the money :D).

In my case I have the following to consider (and perhaps most others will need to consider them as well):
1. R380 Stumpy gearbox A$1575 (not sure if this is the right one)
2. Series 5 speed kit A$600
3.High ratio transfer kit A$425 + $125 surcharge = $650
Sub Total $2825
Plus freight, etc.

Your idea of the transfer box kit is a good one and I have considered it myself, however, compared to an overdrive it has the following disadvantages:
1. I think the transfer box has to be machined - please correct me if I am wrong.
2. If I purchase from Ashcroft the box needs to be sent to the UK, or pay a surcharge and do the work here.
3. Once the modifications are done to the car they really have to stay with the car - an overdrive can be removed and kept or swapped between the fleet.

Decisions! Decisions!

Cheers Charlie

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You are meant to send your transfer box to them as an exchange, however I paid a surcharge to keep mine and they just sent me the already machined transfer case. This way you still have the original case and gears and the car can be changed back to original if required.

This all cost me (including freight) 435 GBP which at the current exchange rate is $717

It's the LT77 gearbox you want if you're going to go a 5 speed, the R380 is way too long. I got one for Louisa's rig for free from this forum. If you go the route of a 5 speed adapted to a Series transfer case you can't combine the high speed transfer case.

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Originally Posted by TJWA

Or you could do what I have just done. Use an Ashcroft kit to adapt the Defender 5 speed gearbox to the Series transfer case. This moves the engine 100mm forward. The engine mounts in a 6cyl are 76mm forward already? So you would need to make some new engine mount brackets to reach forward another 24mm. The Series transfer case has a lower ratio so is better suited to the 4.7 diffs and will give you around 3000 rpm at 100kph in 5th. With 4.1 diffs it would give you 2200rpm. (this is just an estimate, someone will come in with an exact figure to correct me I'm sure).

I'm doing this on a shorty and as yet have not fitted the motor / gearbox / transfer case to the chassis, but the way things are measuring up the transfer case mounts remain the same and the 5 speeds stick comes out of the same hole the Series box did.

http://www.aulro.com/afvb/attachment...7052010794.jpg

By the way, the torque and power ratings for a 200tdi are almost identical to a Holden 186.

Defender 200TDI Power 80kW @ 3900 rpm Torque 255Nm @ 1800 rpm
Holden 186 Power 94kW @ 4200 rpm Torque 245Nm @ 1600 rpm
Holden 186S (2bbl. carb) Power 108kW @ 4600 rpm Torque 249Nm @ 2200 rpm

I think if you drive normally the Series box would be fine. When I eventually put a 200tdi in my S3 LWB Ex Army I'm going to bolt it straight up to the Series gearbox (after I change the bellhousing to a 4cyl).

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This sounds like one of the better and cheaper options as you get the 5 speed defender box but keep the series transfer therefore not having to modify diffs etc - or maybe you do and I missed that bit?

Question: Is the transfer off a 6cly or 4cly?? or maybe it doesnt matter either way?

Jim

"You have to weld the rear shock absorber mounts
Manufacture or move the engine mounts on the chassis
Manufacture or move the gearbox mounts on the chassis
The whole driveline is longer so you need to either move it all back or forward. This means either modifying the propshafts or moving the radiator support forward
Build a new gearbox tunnel to accomodate the new gearstick and transfer stick
Modify the gearstick to move it back or forward so it's reachable in the cab
Modify the handbrake system and lever to fit"

Sure, and none of these require extensive milling, lathing, or engineering shop type work. Like most conversions, these are issues.

Quote:

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Originally Posted by Jimmy

This sounds like one of the better and cheaper options as you get the 5 speed defender box but keep the series transfer therefore not having to modify diffs etc - or maybe you do and I missed that bit?

Question: Is the transfer off a 6cly or 4cly?? or maybe it doesnt matter either way?

Jim

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You don't need to modify the diffs. The transfer can be either a 6cyl or 4cyl, there's no difference.