95 Disco I 3.9 to 300D Turbo Diesel Conversion
First post.. and its going here!
Listen man, I've bookmarked your thread and several others looking for progress and a detailed run through all your trials and tribulations. I think its an excellent swap with it competitive in power with the 200tdi / 300tdi but not near as competitive in the long run and reliability. It's a tried-and-true iron workhorse.
Im going through a OM617 I have in my garage now, and when it's done contemplating this very swap. R380 all the way. I've been on the lookout for 5spd discovery for the last little bit, not much has turned up in my neck of the woods so far (PNW).
Questions though, your wanting to use 240 flywheel back to the clutch, are you still planning on using a lathe to work down the disco clutch disc? Do you know if the throwout bearing will work with the pressure plate (have enough throw / too much?) that would be a concern of mine, I would hate to put it all together and find out that it is not disengaging properly.. would be a real kick in the sack. Might be some other alternatives. Have you figured what you are going to do for a bushing adapter for the input shaft?
I'm glad to see your touching base with your thread, please keep with it, I'll be watching close. Tons of pictures please!
Like I said, I'm thinking this will be my next diesel swap, I just finished one in a 1994 4x4 Ford Ranger. Check them out if you want to and get a chance!
Listen man, I've bookmarked your thread and several others looking for progress and a detailed run through all your trials and tribulations. I think its an excellent swap with it competitive in power with the 200tdi / 300tdi but not near as competitive in the long run and reliability. It's a tried-and-true iron workhorse.
Im going through a OM617 I have in my garage now, and when it's done contemplating this very swap. R380 all the way. I've been on the lookout for 5spd discovery for the last little bit, not much has turned up in my neck of the woods so far (PNW).
Questions though, your wanting to use 240 flywheel back to the clutch, are you still planning on using a lathe to work down the disco clutch disc? Do you know if the throwout bearing will work with the pressure plate (have enough throw / too much?) that would be a concern of mine, I would hate to put it all together and find out that it is not disengaging properly.. would be a real kick in the sack. Might be some other alternatives. Have you figured what you are going to do for a bushing adapter for the input shaft?
I'm glad to see your touching base with your thread, please keep with it, I'll be watching close. Tons of pictures please!
Like I said, I'm thinking this will be my next diesel swap, I just finished one in a 1994 4x4 Ford Ranger. Check them out if you want to and get a chance!
I think your fuel delivery may be too much since the smoke. does it go away after warm?
Drifting
Joined: May 2014
Posts: 25
Likes: 0
From: USA
It does smoke a little more when cold, and when I romp on it without load. Driving around there is almost no noticeable smoke, especially once I'm already up to speed. I'm not into the whole 'smoke show' or 'rolling coil' crap. I did bump up the fuel screw a little bit (has a VE pump.. same type as cummins.. and is fairly easy to mod) after I installed a intercooler, boost, and pyrometer. Had to be cautious about EGT'S especially with this motor (aluminum head). The engine came in a bunch of crap.. Mitsubishi by design.. forklifts.. etc.
Ranger wasn't by dream conversion vehicle by any means, but it was 500$ with a blown engine and hard to pass up. Its a good round town/distance 4x4, nothing to pull our haul or put around low rpms. Pretty RPM happy motor, a lot like the OM617 (mine redlines @4500) 2.3L 80HP @ 120TQ you can see it moved the truck pretty well considering.
Anyways, was just a little motivation and support. Been through a little bit of the hurdles of gas to diesels before. Looking forward to your trials. I just ordered a head gasket and lower gasket kit on my OM617, and will begin getting it ready to go... for something!
Ranger wasn't by dream conversion vehicle by any means, but it was 500$ with a blown engine and hard to pass up. Its a good round town/distance 4x4, nothing to pull our haul or put around low rpms. Pretty RPM happy motor, a lot like the OM617 (mine redlines @4500) 2.3L 80HP @ 120TQ you can see it moved the truck pretty well considering.
Anyways, was just a little motivation and support. Been through a little bit of the hurdles of gas to diesels before. Looking forward to your trials. I just ordered a head gasket and lower gasket kit on my OM617, and will begin getting it ready to go... for something!
Thanks Koldstart for the support and motivation. I just got my phone back so will take a few pics of the parts to go between the om617 and the r380 as well as possible solution for the spigot bushing tonight.
It is going to be sweeeeeet!
PM me and I will give you my number. And BTW that pic is not really me. It is Bubbles ffrom Trailer Park Boys. Awesome Canadian series on their version of Showtime..... which is Showcase. I can watch that shyte all day.!!!!
Last edited by raeuspius; May 13, 2014 at 05:04 PM.
Drifting
Joined: May 2014
Posts: 25
Likes: 0
From: USA
Right on , I will shoot you a PM later, I don't know if I can do it on my phone.. every time I try it takes me somewhere else.. and to think, I was going to compliment you on your lovely eye goggles and hardhat.. should have known!
Winching
Joined: Jul 2010
Posts: 683
Likes: 3
Which shop in Atlanta? Maybe they would be interested in buying mine. I have already had the clutch redone, so it's new in the box. The R380 was falling out of gear so it will require a rebuild kit. From what I gather, it's around 2-3hunderd bucks to order a complete kit.
Welcome to the forum KOLDSTART!!.
To answer your question about lathing the 10" (65.00 at rovahfarm) rover disk, it is either that or change the input shaft to a 10 spline as the Benz clutch disk is or find a 9" 20+ spline disk to mate with the r380 input shaft and fit in the 240 manual flywheel. Balancing of the crank and weight to transfer and maintain torque is main key. The 300GD and Euro 300TD uses a 38lb flywheel for a good weight match of a auto torque converter. I do not want a broken crank after all the work is complete.
So the pilot or spigot bushing issue. I toyed with the idea of a sealed bearing ID matching the input shaft and OD matching the place of the insert portion of the origional torque converter. Bearings wear and tend to deviate the input shaft upon failure so.... I have a hard aluminium disk and a cylinder from an injection / extrusion machine that i may extend the crank with. Of which I can machine the inner bore to accept a bushing.
As for the R380... There is a shop in Atlanta. that imports them rebuilt from UK. For about 2300. You can get one imported direct from Ashcroft trans in UK.
Honeslty as stated before, I never did this before and will not know exactly how the issues you bring up and are in the equation will be addressed until I actually have my motor out and I can see "HOW THE THING WORKS"
I will post pics of my parts used between the om617 and the R380 as soon as I locate my phone....lol
To answer your question about lathing the 10" (65.00 at rovahfarm) rover disk, it is either that or change the input shaft to a 10 spline as the Benz clutch disk is or find a 9" 20+ spline disk to mate with the r380 input shaft and fit in the 240 manual flywheel. Balancing of the crank and weight to transfer and maintain torque is main key. The 300GD and Euro 300TD uses a 38lb flywheel for a good weight match of a auto torque converter. I do not want a broken crank after all the work is complete.
So the pilot or spigot bushing issue. I toyed with the idea of a sealed bearing ID matching the input shaft and OD matching the place of the insert portion of the origional torque converter. Bearings wear and tend to deviate the input shaft upon failure so.... I have a hard aluminium disk and a cylinder from an injection / extrusion machine that i may extend the crank with. Of which I can machine the inner bore to accept a bushing.
As for the R380... There is a shop in Atlanta. that imports them rebuilt from UK. For about 2300. You can get one imported direct from Ashcroft trans in UK.
Honeslty as stated before, I never did this before and will not know exactly how the issues you bring up and are in the equation will be addressed until I actually have my motor out and I can see "HOW THE THING WORKS"
I will post pics of my parts used between the om617 and the R380 as soon as I locate my phone....lol
Drifting
Joined: May 2014
Posts: 25
Likes: 0
From: USA
Im in the process of hunting one down for a swap, like I said above I'm in the stages of gaskets all around for the OM617 I have now, should be here friday. How much do you want for your trans? I've rebuilt one trans before...
Are you still running around in your 95'? Or did you just swap your old one out for another?
Are you still running around in your 95'? Or did you just swap your old one out for another?
I am using my R380 trans. That is the only reason I have kept my 95 is to do the swap. I If you have the R380, take it apart and find you may only need get the syncros and bushings. Gears rarely go. The syncros are brass and to not tolerate sulpher. I would try running full synthetic ATF in your r380 for a week and refill with Redline MTF. The shop in atlanta sells on ebay
http://www.ebay.com/itm/Land-Rover-Discovery-1-200-TDi-1989-1993-Reconditioned-LT77-Gearbox-/271280453455?pt=UK_CarsParts_Vehicles_CarParts_SM& hash=item3f2993374f
you can find them for super cheap. they also fit them in the MG Rv8
http://www.ebay.com/itm/Land-Rover-Discovery-1-200-TDi-1989-1993-Reconditioned-LT77-Gearbox-/271280453455?pt=UK_CarsParts_Vehicles_CarParts_SM& hash=item3f2993374f
you can find them for super cheap. they also fit them in the MG Rv8
Im in the process of hunting one down for a swap, like I said above I'm in the stages of gaskets all around for the OM617 I have now, should be here friday. How much do you want for your trans? I've rebuilt one trans before...
Are you still running around in your 95'? Or did you just swap your old one out for another?
Are you still running around in your 95'? Or did you just swap your old one out for another?
Last edited by raeuspius; May 16, 2014 at 07:06 AM.
Update with Photos
Here is the motor. an OM617 Benz motor. Tat at bottom right is a flywheel and friction plate.
I picked up a manual flywheel, clutch disk, friction plate and throw bearing super cheap!! Actually I have two sets.
This is the Benz 10 spline clutch disk that i want to use but the input shaft of the Rover R380 has 22? splines
This is the crank side of the manual flywheel with my aluminium disk setting on top that may space the flywheel.If you look closely, the inside bore of the disk is close to the OD of the input shaft of the r380.
This shows the larger bore that the torque converter goes into motor side. The Rover uses only a thin bronze (sleeve) or spigot bushing and I need to adapt to the flywheel or get a bearing to close the distance between the R380 input shaft and the bore of the flywheel or crank flange. This auto flywheel is to be replaced by manual flywheel.
I picked up a manual flywheel, clutch disk, friction plate and throw bearing super cheap!! Actually I have two sets.
This is the Benz 10 spline clutch disk that i want to use but the input shaft of the Rover R380 has 22? splines
This is the crank side of the manual flywheel with my aluminium disk setting on top that may space the flywheel.If you look closely, the inside bore of the disk is close to the OD of the input shaft of the r380.
This shows the larger bore that the torque converter goes into motor side. The Rover uses only a thin bronze (sleeve) or spigot bushing and I need to adapt to the flywheel or get a bearing to close the distance between the R380 input shaft and the bore of the flywheel or crank flange. This auto flywheel is to be replaced by manual flywheel.
Last edited by raeuspius; May 16, 2014 at 07:02 AM.