Auto conversion

[cewilson]

I've been thinking about this for a while. My vehicle is a 93 200tDi. What exactly will I need part wise, and approx how much will it cost? I will fit it all myself as it's an easy enough job.

Of the top of my head:

1. ZF? Auto - is the box a different size to the manual - esp length wise?

2. Tailshafts - does it cause a different length to be needed?

3. Mounting points - is it different to the manual?

4. Cooler - where to mount, what type to use?

5. Electronics - obviously the 200tDi isn't - so I'll have to use an earlier box
without the electronics to worry about (well other than the neutral switch)

6. Centre console area - how much do I need to modify etc to make way for the new assembly. Is there parts available or can I do/make something at home to suit?

7. Anything else I've forgotten?

Thanks for any help on this

Cheers
Chris

[Slunnie]

This will be cool Chris.

I've been thinking about this for a while. My vehicle is a 93 200tDi. What exactly will I need part wise, and approx how much will it cost? I will fit it all myself as it's an easy enough job.

Of the top of my head:

1. ZF? Auto - is the box a different size to the manual - esp length wise?
Almost definate that length is the same as the R380, not sure LT77/85, LT95 is about 25mm shorter

2. Tailshafts - does it cause a different length to be needed?
The R380 is the same as the 4HP22, not sure re LT77/85. LT95 is about 25mm shorter.

3. Mounting points - is it different to the manual?
These come off the Transfer case - same as R380 and LT95.

4. Cooler - where to mount, what type to use?
I'll get a pic of what I'm doing right this second. Basically its a D1 ATF.... I think it is anyway, it may even be a PAS cooler, but mounted infront over the steering. This screws direct to the chassis.

5. Electronics - obviously the 200tDi isn't - so I'll have to use an earlier box
without the electronics to worry about (well other than the neutral switch)
Reverse switch, selector wiring.

6. Centre console area - how much do I need to modify etc to make way for the new assembly. Is there parts available or can I do/make something at home to suit?
I'm going from scratch here. New tunnel, but that doesn't mean much.

7. Anything else I've forgotten?
Did the auto ever come with the 200tdi? AFAIK the 200tdi has the old bellhousing pattern that is not compatible with the 300tdi. I'm not sure if there is a 200tdi to ZF belhousing adaption/modification to suit?

Thanks for any help on this

Cheers
Chris

[Slunnie]

Im making assumptions here with the similarities of Series and Deefers.

The cooler I've mounted here:



The tunnel implications may relate to the depth of the selector:

[justinc]

Chris,

There is quite a bit more involved with the 200Tdi to ZF. They weren't available here in OZ in the RRC or early D1, the adapter plate etc from the 300Tdi to ZF won't fit and the engine is offset in the 200Tdi defender more than the 300Tdi is, and the floor pan and seat box is different to the MA series 1994 onward 300Tdi etc(Not that is really an issue with an auto conversion)

You CAN do it, as Simon says the shafts etc will end up in the same place and it would be easy to find plenty of room for the cooler etc... it is just a whole lot easier to use a 300Tdi 1994 onward Defender... I have done 2 of those and they are a great result as I used a complete Donor Disco for one of the conversions.



JC

[Slunnie]

Chris,

There is quite a bit more involved with the 200Tdi to ZF. They weren't available here in OZ in the RRC or early D1, the adapter plate etc from the 300Tdi to ZF won't fit and the engine is offset in the 200Tdi defender more than the 300Tdi is, and the floor pan and seat box is different to the MA series 1994 onward 300Tdi etc(Not that is really an issue with an auto conversion)

You CAN do it, as Simon says the shafts etc will end up in the same place and it would be easy to find plenty of room for the cooler etc... it is just a whole lot easier to use a 300Tdi 1994 onward Defender... I have done 2 of those and they are a great result as I used a complete Donor Disco for one of the conversions.



JC

JC is it a bolt out/in job to change to a 300tdi in the process?

[justinc]

JC is it a bolt out/in job to change to a 300tdi in the process?

Hi Simon,

Well yes and no.
The engine mounts and the whole position of the engine in the engine bay is different. The 300Tdi sits much further forward, (About 10 inches I reckon) and centrally, which means the engine mounts to chassis etc are completely wrong, the bulkhead shape is designed to accomodate the 200 Tdi which is offset to the left (Like a series) and the possibility of the 300Tdi turbo and manifolds getting in the way of the LH inner guard are high unless you take the opportunity to change the position of everything, tansfer case bracketry etc etc to centralise the engine and trans assembly under the floor pan.
If changing to an auto, it wouldn't be that hard really. I wouldn't recommend it otherwise as the LT77 won't fit up to the 300Tdi easily(And why would you???) so you'd have to source a R380 bla bla, easier to just change vehicles in that case
In Chris' case, I'd possibly go with trying to source a 200Tdi to ZF adapter etc from the UK, as lots of RRC's prior to softdash were available with this combination AFAIR. It'll look very neat if done this way, and he gets to keep that fantastic 200Tdi engine

JC

[George130]

Have a look in my gallery. There is a few pics that show the cab mods.

[cewilson]

So Justin - the hassle as I understand it is the adaptor plate, which can be sourced in the UK?

I thought that the length and the cab were going to be the hassles, but maybe not. Would you just use a box out of a 300tDi Disco for the conversion?

And is the engine offset a problem with the auto box? Or will it still line up Ok?

Cheers
Chris

[B92 8NW]

So Justin - the hassle as I understand it is the adaptor plate, which can be sourced in the UK?

I thought that the length and the cab were going to be the hassles, but maybe not. Would you just use a box out of a 300tDi Disco for the conversion?

And is the engine offset a problem with the auto box? Or will it still line up Ok?

Cheers
Chris

ERR4612, adaptor plate, 200Tdi to automatic gearbox. Like trying to find a needle in a haystack.

[cewilson]

I've read on a couple of the english sites that the 200tDi mated to the auto is very sluggish, as opposed to the manual.

Does anyone here know anything about this? Or is it another case of people commenting on something they've never tried or owned themself?

Cheers
Chris