Disco I: 5-Speed Diesel Conversion

Scott Brady

Founder
As I grow restless with my truck being "finished" and the Trooper holding the record of the longest I have ever owned a vehicle (5 years) and the Jeep going to ebay/autotrader in a few weeks I would like to spend some time reviewing options for a solid replacement, but with good mileage.

It is not because $3.00 a gallon has any real impact on my budget (we drive very few miles per year in our DD, living in a small town), but because I am very interested in the efforts required and results of converting a nice SUV (for storage volume, transporting people and safety) to a fuel efficient solution.

I know there are other vehicles as options, like the 60 TLC, but the LR seems to be the perfect solution for my needs. Compact dimensions, great utility and excellent trail performance with minimal mods. I am also a hopeless Camel Trophy geek, so...

This will be a place holder for some research and feasibility. I know that several companies are bringing in the TDI and I have some good contacts in France too.

My opinion is that I can buy a new car for $40,000 (like the GC CRD) or build my own, with all of the best components for trail and reliability and still get mid to high 20's on MPG.

When in France, I drove a 2-door Discovery I with the little diesel and I loved that truck. We consistently got 28-29 mpg on the roads.

Base vehicle:

1997 Land Rover Discovery with 5-Speed and Cloth interior. Goal would be to find a reasonable mileage vehicle with really straight body and clean interior. Something from CA, AZ, NM would be ideal.

Considering swapping the doors out to manual locks and windows

Rebuild the axles with ARB/Maxi-Drive, new T-case and updated 5-speed

I am not sure on the project timing, as it might even wait until after South America, but I thought it would be a fun exercise regardless.

A little inspiration: :drool:

mpi01.jpg
 

The BN Guy

Expedition Leader
This may be kind of a rookie question but can you get the diesel powered rigs here in the states? I'd even settle for an older one if need be.
 

stevenmd

Expedition Leader
Scott - there is a guy in Reno who brings in TDi's and so forth. They even do the work of installing it if you don't want to do that yourself. If you want it, I'll look for his number.
Also, check out lrx.com ~ there is a gal named Linda who was selling a 1996 DI with manual tranny. I don't know if it is still for sale. She is in Los Gatos.
 

nvprospector

Adventurer
As for the t-case there is no need to replace that. The LT230 is a strong, gear driven t-case with a long history of reliability. For a pre DII t-case all you need to do is update the rear output seal to stop the chronic leaks they seem to have. If you are looking for lower low range, contact Bill over at Great Basin Rovers in Utah, he has a killer low range kit that I have in my rover. The only t-case low range that I have seen beat it was the Atlas t-case. Also Bill makes drive shafts that I just love and has a kit to get rid of the stupid Rotoflex. http://www.greatbasinrovers.com/

The DI axels are strong, full float systems made from 3/16 steel at the carrier flange. I used the electric locker system from KAM Differentials and love them. They have been in my DII going on 5 years now and would never think about the ARB system. JM2C http://www.kamdiffs.com/difflock_pricing.htm

To make the underside bullet proof look to http://www.rovertym.com for all these needs. Again, some of the best products I have ever used and when you talk to them they will help.

If you are not getting one that has a TDI, I would highly recommend a 300TDI. It is the most robust diesel out there IMHO. You can do a lot the TD5; even smoke your tires with the right computer. But that is the key word on why not to get the TD5, COMPUTER. The TD5, which is easier to get but the 300tdi does not use a computer. Don't even look at the 2.5L or 200tdi conversation as so many in the states do. I was very disappointed with the performance of a 2.5L that was put in my friends rig. It does not have the upper end to sling a 6000 pound monster around in traffic, and does have problems off road when you have the t-case and diff's locked. That is why I opted to spend the extra $$$$ to get the 300tdi from England. There is a guy on ebay, have to find he site again, that I got my engine from and it only cost $4,000 with shipping. Just got it in this morning and it looks pretty :drool: . But most people pay well over $6,000 go get a 300tdi into the country.

Good luck
 
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pwc

Explorer
The 2.8L International may be an option but the 300TDI will be cheaper. It's being replaced by a 3.0 CRD I think.

As for transfer case, I've got a 1.4:1 for sale. :) But I guess that is going in the opposite direction from +MPG. Some people claim you need the 1.4:1 if you're going too heavy but I'm putting the 1.2:1 with a ZF and 2.8L, so in a few weeks I can tell you how that goes.
 

The Swiss

Expedition Leader
nvprospector said:
Don't even look at the 2.5L or 200tdi conversation as so many in the states do. I was very disappointed with the performance of a 2.5L that was put in my friends rig. [/SIZE][/FONT]

Good luck
Well, the 2.5L TD for sure is not a powerhouse, but in the LandRover 90 I had in Switzerland, it wasn't a dog either. Bigger problem was the engine design, that it basically was the naturally aspirated engine with a Garett turbo bolted on. Most turbos leaked oil into the air filter; so did mine. On the positive side,it was the last fully mechanical diesel Land Rover made, with mechanical everything including the fuel pump.

200Tdi or 300Tdi? Both have advantages; the 200 Tdi was more economical and more reliable, the 300 Tdi a little bit stronger and more refined.
 
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stevenmd

Expedition Leader
thallca said:
I to am looking into the idea of converting my 1989 Range Rover's to diesel. While researching the idea I came across this long thread on the D-90 fourm about replacing their 3.9's with the 2.8L powerstokes. There is a lot of information from several Defender owners who did the conversion. You can find it here
http://www.d-90.com/forum/showthread.php?t=4200&page=1&pp=15
Nice find dude. Did you go to RR this past weekend? If you are interested, the NCLR is doing a week long Oregon run the end of June.
 

thallca

Observer
stevenmd said:
Nice find dude. Did you go to RR this past weekend? If you are interested, the NCLR is doing a week long Oregon run the end of June.

No, I haven't been able to do much in the way of off-roading lately. Too, much work and not enough time off...
 

Jonathan Hanson

Well-known member
Scott, our research into this possibility indicated that the R380 five-speed in back of the petrol V8 is different from the one behind the diesel (ECR's site), apparently in more than just the bellhousing. If so, the only advantage you'd gain by finding a five-speed Disco donor is that the pedals and master cylinder would already be there. You might have an easier time finding a much-more-common automatic in the condition and color you (or Stephanie?) want, and installing your own pedals. Not sure what's involved in that.

I see a comparison test in our future: Disco turbodiesel versus FJ60 1HZ diesel!
 

Scott Brady

Founder
Niel,

Great link, thank you.

The more I research this project, the more feasible it becomes in my mind and the simplicity gained is impressive. The challenge would be the tire required, as I would want to do the conversion myself to be able to service the vehicle.

I am also looking into importation possibilities :)
 

JohnC

Observer
Here's what I had planned on doing:

Trade my 4.6 for a 300TDi in Argentina while I'm down there. Most of the guys down there would die to have the V8...
 

Christophe Noel

Expedition Leader
Scott, Let me know what you dig up with regards to importing. I assume you're thinking France? I lived in France for 4 years (not too far from your Outback Import friends south of Avignon) and when I returned home I imported my Ducati 916. Seemed easy enough at the time but this was 10 years ago. We go to France every year and I always see vehicles I'd like to bring home. Keep us posted on what you find out.
 

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