1999 Disco I 300TDi: Fixes, Mods, & Trips

NW40

Explorer
I’ve been in the market for a vehicle that would be suitable for both daily commuting and weekend exploring with or without the family, and with my wife’s preference for a Discovery (I love ‘em, too, but it makes it easier if the other half is onboard!), I finally pulled the trigger Friday on a 1999 Discovery I SE7 with a 300TDi conversion. (Shhhh, don't tell my Land Cruiser buddies!) I'll use this thread to track the Disco's maintenance, mods, and trips.

The day she became mine. An entirely stock SE7, except for the TDi conversion:
photo.JPG


The 300TDi has about 100k miles on it, and the rest of the vehicle is at 179k. I climbed all over the truck for a couple hours as well as put it through a pre-purchase inspection at Lamorna Garage in Seattle to minimize any surprises, and while there weren’t any alarming issues, it does need some TLC to put it back in tip-top shape. A summary of the obvious issues:

Shocks, springs and bushings look about 100k miles past their prime (gives me an excuse to put a lift on it!)
Tie rod ends have play
Some hoses need replacing
Front diff rear seal is leaking
Diffs need an oil service
Sunroofs are leaking
Tires are shot (Look on the bright side...I can install some KM2's!)

Oh, and upon bringing the Disco home, I discovered the fuel tank leaks when parked facing down a steep hill with a full tank. Bummer, but what’s a 15-year old car purchase without some surprise.

On the fun side, I’ll also be adding a bumper (Tactical Rovers, maybe?), winch, and some form of compressed air (York or Sanden OBA possible while keeping A/C?). Down the road, when funds build back up, I'm leaning towards installing rear HD axles and Detroit locker. It sure is fun building a wishlist!

I’m really stoked to get this Disco ready for the trail this summer. Hope to tackle much of what needs to be done in the next few weeks before a trip in June with my local club, Northwest Overland.
 

NW40

Explorer
Now that I have the introduction out of the way, I'll say I don’t know Discos, and have fairly limited wrenching under my belt. A few questions for the Discovery owners out there to get me started:

Where’s the best place to pick up a Factory Service Manual? Preferably for the 300TDi Disco, but a NAS Disco manual will certainly cover most of what I need to see.

Where can I find exploded parts diagrams?

Which Land Rover supplier has the best selection and prices?

Any recommendations for which bushing kit should I purchase? I noticed Lucky8llc.com has 4 different levels, Comfort to Hardcore Performance:
GAL105B Discovery I Complete Bushing Kit- Comfort Polybush $238.00
GAL105D Discovery I Complete Bushing Kit- Dynamic Polybush $238.00
GAL101R Discovery I Complete Bushing Kit- Performance Polybush $238.00
GAL108R Discovery I Hardcore Complete Bushing Kit- Performance Polybush $325.00​

Hoping to install bushings and a Medium Duty OME kit this weekend. Any other parts I should gather while I'm up to my elbows in the suspension?
 

NW40

Explorer
Thanks, Scott! And I think "awesome truck" most certainly applies to your D1 as well! I've been reading your build thread, but at well over 100 pages, I've got a ways to go.

Any input based on your own Disco build with regards to which OME kit to go with? Medium or HD? This being a dual purpose truck, I'll be doing a fair amount of unladen daily commuting (pretty much 5x/week), but with a family of 4, we definitely load up for overlanding trips. I'm leaning towards medium duty with some helper springs in the rear, but am open to input based on others' experience.

And have you replaced bushings? Which did you go with?
 

Scott Brady

Founder
Get the Land Rover genuine HD springs. http://www.roversnorth.com/ProductDesc.aspx?code=NRC8044
http://www.roversnorth.com/ProductDesc.aspx?code=RNK5103&type=3&eq=&key=it

Install bone stock new OEM shocks. http://www.roversnorth.com/ProductDesc.aspx?code=STC3703

The older Old Man Emu shocks were great. The Sports are just too firm now, short of a full expedition load.

You could also go with OME Medium in the front and heavy in the rear.

I am looking at swapping all of my springs and shocks out. It is set up way too heavy and I don't load the vehicle much anymore beyond a few gun cases
 

Mack73

Adventurer
Glad to see someone finally picked that up. Wish I had that much spare cash to grab it - it looked like a good one.
 

LR Max

Local Oaf
On the springs, depends.

If you aren't going to weigh it down with winch bumper and a crapton of crap in the back, get OME MD's. They will give you lift without killing ride or flex. OME HDs need a decent amount of weight to actually make them work. And on that note, more than just a winch bumper, winch, and some crap in the back. Like, A LOT of weight. I kid you not, OME HDs can and will kill your flex. On the D1s that have no traction control, this is a problem.

With Lucky 8 and Rovertym now, you have a lot of options. Just keep looking around.

For bushings, go OEM. I know they aren't cool bright colors but poly bushings can be too rough and you'll feel it in the ride.

The sunroofs are always a problem. Do research on the best way to fix em. If you don't care, you can just seal them shut. However a D1 on a nice day with the windows down and sunroofs open is mighty fine.
 

ZG

Busy Fly Fishing
Nice find! Who did the conversion? Can you post some photos of the engine bay?

I'd go with LR HD springs if you want to keep a nice ride height if you're not adding larger tires.

Genuine bushings will be the best. The only advantage poly has is price and ease of installation in my experience.

I'm not sure you'll be able to do an engine driven compressor for on board air AND A/C, but I suppose anything is possible.
 

roverandom

Adventurer
Daily commuting and weekend exploring? Keep it stock. That is what they were built for. Just get an extra set of wheels with dirt grip tyres for the weekend and your good to go.


Stock DI's are surprisingly capable off road. I suggest taking it out a few times to see what you really need as opposed to what you think you may need. I'm assuming you went with a Diesel because it is cheaper to run than the stock V8? No need to load it down with stuff you will hardly ever use.

My 2c.


Sent from my iPhone using Tapatalk
 
Last edited:

Scott Brady

Founder
Good advise here. I ran my Disco almost entirely stock for over a year and was seriously impressed with the performance. Maybe some rocker protection in addition to the slightly taller springs and +1 tire size. I still run 245/75 R16 on Discovery and have run some pretty tough trails and long trips with it.

10012881_10152792694473275_7650893453038240793_o.jpg
 

timmy!!!!!!!

Explorer
With the diesel up front won't he want a stiffer spring anyway? The aluminum V8 is considerably lighter than the 300tdi.

Rocker protection is key on these discos along with diff guard. Other than that I would just trim the front bumper and get a genuine front winch tray with 235/85s or 245/75s and call it a day.

Scott's truck inspired me to get rid of my Low Profile SD rack for my D1... but it is considerably built up.
 

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