Got the VIN plate transferred. Bigger PITA than I thought and I slightly mangled it in the removal, but it’s as clean as I can get it.

The old harness is removed and I’m all set to route the new one into the dash.

 

OK, I’m FINALLY ready to get the dash reinstalled. Now that I’ve been messing with things here and there, I feel really familiar with all of it, and it’s not nearly as intimidating as when I started. I even test fit the center stack to make sure all is well, and I should be good to go.

To that end, I understand why those center stack parts always get broken. The fit is pretty tight, but not really very precise, and based on that plastic not being the strongest or most pliable, it would be easy to break.

I pulled the OEM radio support again as well as I think it will put less stress on everything. This was the one from the original stereo install.



But routing the harness was super easy since I’d kinda studied and planned it a good bit and I kept every single clip and such and it went in perfectly.

I’m pretty sure I will still need help to get it placed initially but we’ll see.

Lastly, always being the opportunist, I found a set of Comet wheels with new BFGs on them. I’m not a huge fan of BFGs for our climate here in the mountains, but a few hundred is dramatically cheaper than the $1500 it will be to put on my existing Comets. It’s pathetic as I now have 4 sets of wheels and once I get going on the Giverny and have the original Comets refinished, I’ll be getting rid of a couple sets.



I think this will allow me to do some more aggressive off road stuff, so I might embark on some stuff in the coming weeks and months.

 

Ah heck with it! I can dooooo eeeeeeeet! Got it in without breaking anything, pinching or screwing up any wires, and really without any drama. I started all the main bolts and have a good number of the electrical connections plugged in. So now just to get it all back together.

I make one mistake: I didn’t route the clock spring correctly, so I have to go upstream to unplug it, but I’m pretty happy thus far. I sure hope everything works.



So then, knowing what I know now, it’s not that big of a deal. It really is just the volume. I have at least 3 hours or so of finishing things up to include getting the seats back in.

PHEW!

 

Well I decided not to work out as you all know the drill when you start to see a light at the end of the tunnel.

I’m about 2/3 of the way done with the dash stuff. I had to pull a couple things out and reroute some wires correctly for the cluster surround buttons. Once again, I understand how the cluster surround gets cracked and mangled as the wire management there really isn’t the greatest and seems more an afterthought. The mount for the cluster itself on the other hand is mounted about a solid as could be. Kinda dippy, but follows much of the design characteristics of the Disco; some things are incredible and durable, some are kinda poor attempts.

As is the case in many engineering exercises, it could very well be a result of multiple engineering teams working on different components and some knocked it out of the park while others were more interested in getting to the pub.

Anyway, a couple progress pictures.





I am going to hold to my statements about the Brits and the different engineering philosophies toward fasteners and such. The sheer number of tools required to do what was really some simple stuff this evening was kinda silly. And they are all are different sizes and I used everything from 1/4-1/2” sockets, deep well and regular, box wrenches of various sizes, nut drivers, and blah blah blah.

Meh, I’m not upset in the slightest and again, broke nothing and took my time. I’m pretty excited as driving the Jeep and S4 are fun, but as we all know, there is some wacko addiction that the D2 creates. I stopped so I can make dinner since I’ve got some early wake up calls for some important work stuff. I caught myself getting a scoshe frustrated from time to time and quickly stopped for a moment and remembered it’s a toy and this is to be fun- which it has been.

 

That's one of the things I appreciate about my Colorado. The entire dash comes apart with a 10mm socket, a philips head screwdriver, and one trim tool

 

Yeah I don’t get it. After years of working on Jeeps, a number of German cars, and with the catalyst to this thread now British machines, I struggle with the penchant to make things far more complex and in an afterthought way in which they do. Oh well.

I used to say my Jeep took violence sometimes, but if you ever did that with a German car, you would break things. Additionally, zee jermahns force you to follow a specific way of putting things together in a specific order, whereas Nigel just says “heck with it, just throw a bunch of bolts on it until it won’t fall off. Oh, we ran out of that type, well, we have a bunch of these other ones in the bin, just use those.”

 

I keep piece parting away at getting it done and I’m rapidly getting to where the seats are all I have left to do.



It’s going pretty smooth and no big gotchas or concerns. Obviously I get nervous I’ve forgotten something, but I think I’ve got it all there.

One thing I will say. If anyone decides to undertake this, something that has made it WAY easier is to remove the front seats. I’m a fairly tall dude at 6’7” and not having to fold up like a piece of origami made getting this stuff done so much easier. And frankly, the carpet is comfy to sit on as you work.

 

DONE!

A couple observations:
- It took entirely too many tools to do this
- I thought I remembered when messing with the plugs and switches, they were set up to only go in one spot. WRONG! I’m glad I didn’t put anything final in the center stack as I had to rearrange pretty much every switch. I now probably have to remove the cluster surround too as the last ones to correct are the the front fog lights and fuel door
- Doing the foam for the flaps and HVAC box made a HUGE difference. I mean MASSIVE. Air comes out the vents more and I think it will now turn the interior into an ice box or sauna depending on what I need.

I took it around the block and verified everything functions like HVAC, stereo, wipers, etc.

Would I do it again? Absolutely. And I will have to do it again in the Giverny (already have another dash for it). The only thing that broke- or was actually already broken were the tabs for the A Pilars. I’m pretty knackered as I’ve had long days at work the last couple days, but I’ve got it done and am very satisfied.

At least now I won’t have to use the Jeep to pick up the family when they arrive next week. I can’t wait to see my wife and children again.

 

Well, get me back in the States and allow me access to my tools and I can get some stuff done. Tonight was getting the “new” wheels mounted. These are 265/65 R18 BFG KO2s. They are the exact same height as the 265/75 R16 ones that came off. I think they might be ever so slightly more narrow, but I like them a lot.

I had KO2s on the Blue one and they rode fine but didn’t impress off road. Obviously I’ve not been off road with these, but they ride WAY better than the Coopers on the 16” wheels. I just went for a drive and it is significantly more smooth at 75 mph, so in terms of a stop gap tire until I get the original Comets refinished, these are going to be great. I drove for a few miles from 50-t-mph on a dirt road that had a bit of washboard here and there and again the ride was great.

Handling is better and a bit more predictable, but cornering is probably the same. As they are used tires I’m not pushing at all, but on the whole I like them and I feel I can drive at freeway speeds better now.





He didn’t want to let go of the 5th wheel, so I just used one my existing Comets (the spare he had didn’t have a KO2 on it anyway).

So the only thing I need to address right now is the A Pilar interior trim. Honestly, I think I’m going to do what I read some folks do externally and just drill and use a trim screw. It’s a better solution than OEM. If I don’t like it I’ll just find some used ones or grab the ones from the Giverny.

One last thing that I noticed, and it was happening with the other tires, is that above 70 mph when I coast, I get very slight vibration. It’s not bad but I’m a nut about stuff and get concerned about everything from driveshafts, to diffs, to even the T case and transmission. I’ve got a greasable shaft in front, but not really checked the rear at all. I know there is a balance deal in there but I’ve not inspected or checked the guibo, so those are now on the list.

Anyone have any ideas?

 

Now this is funny. I took the Disco to work today just to make sure everything is OK. My goodness. It is like a new car. So smooth. And the AC…. Cruising at 75 mph and I don’t need the fan past position 2 to make the cab darn chilly. All worth it.

That’s the good news. Bad news is I got home from the office- never even turned it off- and went and played in the pasture on the property while running the dog around. It stalled. Now it won’t restart. It cranks at catches but most times immediately dies. It might sputter a few seconds, but then dies.

I thought the fuel pump, but it keeps catching. I called Tom at GBR and he agrees I’m barking up the right tree, but I can’t get it.

- I’ve swapped the fuel pump relay
- Cleared codes
- Checked fuses
- Checked the inertia switch (I’m assuming it’s ok because I can’t push it down)
- Disconnected the battery for a bit and touched the cables together to drain the capacitors

I get an “err” some times on the UG/. I’m kinda lost on to do next other than check the fuel pump, but it keeps wanting to fire. I don’t think it’s the CPS, but I dunno.

It was all fun and games….