Thread: Stage 1 3.5 exhaust manifold to Disco 3.9

Only place i could see a problem would be over the X member were as s3s1/county/rangie this is removable and probably different to the series chassis as for the manifolds they may be different tho id doubt it ...

Also you should remove the series x member and fit in the removable one from the later rovers as this will make getting the gearbox in and out easyer than having to come in through the top ...

Originally Posted by lokka

Only place i could see a problem would be over the X member were as s3s1/county/rangie this is removable and probably different to the series chassis as for the manifolds they may be different tho id doubt it ...

Also you should remove the series x member and fit in the removable one from the later rovers as this will make getting the gearbox in and out easyer than having to come in through the top ...

Its a prob over the really big deep angled Xmember, and the exhaust pipes come out quite wide when they will only juuuuust clear (if at all) the sides of the chassis. The Stage 1 exhaust system which I've still got comes in closer and rises over all of the xmembers. Its a shame as the Disco one is quite a nice exhaust system.

Actually, that Xmember I need to notch too. Is the removable Xmember really rigid? I ask as this truck is being built for Tuff Trips and its a major section.

Yep its fairly rigid and has 8 bolts about 13mm in dia holding it in place the bottom 4 sit below the rail in amounting bracket and the top 4 go through the rail and have crush tubes inside the rail your D2 has a similar set up and im sure the removable X member has more clearance on the top side and its also easy to chop some of it away to make more clearance as it can be taken out and modded then simply bolted back in and it wouldent be hard to reinforce the whole area by welding doubler plates to the outsides of the rail some simple engeneering could make it clear and be totaly bomb proof

I know that standard Rangie headers wont fit the stage 1 V8.
Dunno if that helps. & the only reason I was told was the bolt pattern is different.

Stirlsilver has the header type manifolds on his stage1 v8 , shoot him a Pm

Thanks for this fellas.

I've just been in at work doing the exhaust conversion tonight. As I was hoping that they would, the Stage 1 manifold and the 3.9 Disco header will directly swap over with minimal fuss, and the exhaust system plumbs straight in. I'm a bit unsure of the exhaust crossing over directly under the ZF sump, but I'll see how it goes when I put the motor in with the Xmembers.

Go here to see the photos that I took when I swapped from the cast manifolds to the EFI manifolds. Hopefully it helps you out!

Series III Stage 1 with a bit of a difference

Thanks for that Stirling. Did you notice much difference in the performance when you changed to the different exhaust system?