In the next 3-4 years, I would like to take my Disco with me ouside the US and drive across Africa/Middle East/Europe/Asia/Australia. Obviously, that's a huge and time consuming undertaking that's going to rack up a lot of miles and to take a long time to prepare for. I've got a few questions and concerns for you guys.

Engine/Trans:

The US spec 4.6 V8. I don't know if I trust it for a trip like this. It's not reliable and outside the US I predict parts will be harder to find than for the diesel. I also don't trust my current transmission because sometimes it acts... funny. I'd like to swap a manual transmission and a different engine. I'm thinking a 350 with Vortec headswith all new bearings, bored 10 over, port and polish, an aftermarket truck cam, ditch the AC. Then probably a T5 transmission. That, or stick with the engine I have and throw on a new water pump, oil pump, and drop the auto trans for a new manual from the UK. To be honest, I'd like to keep the Rover V8, I just don't know if I can trust it on a trip like this. I'd love some feedback.

-=-=-Edit: What about sticking a T5 between the Rover V8 and the Rover Transfer Case?-=-=-

Drivetrain:

HD Axles, 4.11 gears, one Detroit locker and one Posi-, keep 4 extra hubs, all new brakes, 16" rims with really aggressive ATs or maybe MTs. That, or throw on some 2500 Silverado axles. Thoughts?

Suspension:

I'm thinking stock suspension design with a 3" lift, all new bushings, and replace the watts with a panhard. Simple enough.

Exterior:

Rock sliders w/ steps, steel bumpers, Winch on the front with recovery points front and back. No question.

Storage:

I'll need a roof rack, probably full length. Bolt some metal storage boxes to it and weld some sort of locking mechanism up on each of them. Probably 4 of the large brown metal boxes you find at the Army Navy store and then water-resistify them. Put a metal floor in the rest of the rack and keep a bunch of bungees. Also some jerry can mounts. Four?

Interior:

Gut it. Everything except dash, two seats, door panels, A and B pillar trim, and center console. Rubberize or bedliner the floor and make some additional storage in the back across the entire floor that can be opened from the top and that I can have an air mattress on top of. Gonna need a cooler, too. Replace all the door weather stripping, maybe some weatherproof seat covers.

Cooling:

Chevy truck radiator with electric fans and an inline thermostat.

Electronics:

Assuming I keep the Rover V8, how can I waterproof the electronics? I'm about two turbo couplings and a trimmed quarter panel short of a snorkel, so I'll be throwing one of those on no doubt. I need a way to waterproof all the sensors and onboard computers. Of course, a carb'd 350 wouldn't pose this problem, but that sure is a hell of a lot of fab work to complete the swap.

That's all I can really think of. I'd love some thoughts, feedback, ideas, and to be told of anything I've missed. Thanks guys!

 

2 things I do not recommend.

1) Ripping out the interior carpet and spray down bedliner. If you plan on driving across anywhere warm, you'll instantly regret it. You have no idea how hot it gets when you pull that carpet up.

2) Being an American and driving across the Middle East.


If you are concerned with finding parts for your US spec 4.6 outside of the US, what makes you think 350 Vortec parts will be more readily available in the Middle East?


If you are serious about doing it, I would recommend a Toyota Tacoma or Hilux.

 

Ok, I'll definitely listen to both of those then.

For the 350; I don't really think it will be easier to find parts, I just think it would be more reliable. That said, I'd prefer to keep the 4.6.

 

Do it! Make sure your truck is 100% before you embark on the trip. Start with the engine and cooling system. Consider getting your engine diagnosed, find out if it has a slipped liner, find out if the head gaskets leak, find out if the engine has damage due to overheating, etc and consider rebuilding the engine or investing in a professionally rebuilt/upgrade 4.6 engine with top hate liners. Next replace all the cooling hoses, radiator, thermostat, water pump, cooling fan, belts, pules and the oil pump. Next make sure all your fluids are new and clean. Make sure your brake system is in good shape, check the brake lines for signs of rust or punctures. Next inspect your suspension. Your springs may sag a bit because of age and if you are planning on loading up your truck with lots of gear and supplies then you may want to consider installed a new heavy duty suspension lift kit. Next check all your wheel bearings for any signs of wear. How about your front driveshaft? Is it the factory shaft or did you already update it to the aftermarket fully greaseable driveshaft? The factory shaft is a notorious weak point on this truck. Hows the exhaust system? On such a long trip you will want to maximize fuel economy so make sure all your mufflers, cats and o2 sensors are in good shape, when they fail it decreases the vehicles fuel economy. Consider a dam good set of tires and consider getting 2 full size spares. A on board air compressor would be a good idea. Especially if you end up driving through any cold climates where the roads are covered in snow and ice, and also good for regions where you may be driving through desserts where their is sand and lose dirt for roads. Airing down your tires on these roads will maximize traction, then when you reach paved safe roads again use your air compressor to put air back in your tires ASAP. A communication system or navigation system and great map reading skills will be very important on your trip. A dam good emergency med kit and a road side repair kit and tools will also be critical. Try to put a caravan together. The more people that join you the safer your trip will be.

Dont let anybody tell you that you cant do a long trip in your Rover. Some people was more pessimistic than others. Japanese vehicles may be reliable but are probably less capable and are butt ugly! Ive heard stories from true Land Rover enthusiasts who dare embark on long journeys that most others dare not do and they had no problems. ALL vehicles have issues and all vehicles break down when maintenance has been neglected or when the vehicle is abused or pushed hard. So weather you own a Land Cruiser or a Discovery 2 I would still recommend everything above because the last thing you need is to have a vehicle breakdown in the middle of another country.... and I would advise you consider skipping or making a detour around the Middle East right now....... Good luck and thank you for taking an interest in such a adventure of which these vehicles were intended! Remember that before the launch of the first Discovery 2 Land Rover jave a group of journalest to of these new models and had them drive around the world.... they made it in their D2's with no major issues. That was back in 1998-1999:

So do it and dont be afraid to have fun in an amazing vehicle!

 

Depending on where you want to go first, you might find it more cost effective to buy a vehicle abroad and have a company like Foley's or Nene Overland expedition prep it for you. Fly in, pick up the truck and go drive it.
If you buy an older vehicle you Can always bring it back with you once you're done adventuring.
My 109 with a 200tdi is about to make the trek from Europe back to the USA. Roll on, roll off cost is about 2300 to Tacoma, wa from Southampton.

 

Alright, that's what I'm looking for! Let me see, I have no slipped liners, just replaced head gaskets and rebuilt the top end but a top hat 5.0 block would be nice if I can afford one and the trip, I'll be doing a cooling system overhaul in the next few months anyway, I've already got electric fans to go on, I've done the 60k change but I'd do it again right before the trip, I've got new brakes and rotors but I'll need them again by then and might as well do extended brake lines too, suspension is within spec but it would get new TF 3" kit before the trip anyway, It's got two new wheel bearings but who knows what theyll be like when I leave, it does have the greasable driveshaft, exhaust is all new including sensors, two full size spares sounds like a good excuse to get a set of steel rims so all the wheels match, I've got an air compressor already, I'll be investing in a CB and I can read a map, I've got a first aid kit that's about two scalpels short of a hospital, I keep literally enough tools in the back to do head gaskets or whatever the hell else just about anywhere, and a caravan would be really cool.

Everyone seems to recommend avoiding the middle east. I'll go ahead and mark that off of the list, sadly.

Much appreciated!

 

For tires, I was thinking about Nitto Trail Grapplers. They seem to have good tread life and extremely tough sidewalls. Any thoughts on that?

 

Having travelled in land rovers then may I make a few suggestions

I would keep the petrol engine. I have travelled to Africa in both petrol and Diesel engines. The quality of some of the diesel was questionable and we quickly went throught the diesel filters. I would take a petrol engine and put in an in line filter. Cheap and you can bring extras for little weight and space. The electrics on the discos are normally pretty good. Yes we complain about the coil packs at the back of the motor but it's well protected. I wrap the wires ands the top of the plugs with densel tape and did not have problems.

As for the transmission then as long as it's rebuilt you should not have problems.

Suspension. I personally would not go for a 3" lift. I would stick with a 2" lift. When you go higher then you are throwing your centre of gravity out. Even more so when you add a roof rack on there. That brings be to another point. Every one over loads there racks and then you will find that the gutters start to crack. As you are stripping the interior then I would but some kind of partition in the back then you can keep the heavier things in side and lower down. After the first trip then we did that placing the fuel and water in side at the back. Try lowering full fuel cans up and down in the sun in hot humid countries. Also there is less chance of having it stolen.

Speaking of security then I would go for window guards as well. Also a safe for documents and personnel items. Keep nothing on the out side that you cannot live with out or need to keep the vehicle moving.

Dual batteries and on board air will make you life a lot easier as well

Take plastic pens trinkets and sunglasses to give away. I won't say bribe but a helpful donation can get things moving along.

Be careful of taking cb radios. Some countries do not like them and we had one ripped out of a Range Rover once at a boarder crossing.

One of the most useful tools you can take is patience. At a boarder crossing once we were held up for 18 hours. Nothing else to do but get the camp stove out and make a cup of tea. Don't get annoyed with beauracrats.

The best tyres I personally found was Michelin XYZ. They offered the best compromise in all different kind of terrains. Take extra inner tubes!!!

You will find all kinds of information and what works for one person will not work for another

 

I don't know about the truck but IMO you/we are defo targets so the middle east and parts of africa and asia are no go areas for us. Be selective on where you trek and stay.

 

Great, suggestions brought on by experience are the best kind. I definitely want to keep the gas engine. I did not know what you said about the iffy diesel, but I did know that I can do just about anything to a gas engine but have almost no knowledge about diesel engines. I will be sure to add an in line fuel filter. I'll also call around about having the transmission rebuilt. I also have an extra out of an '04, so I could actually have that one rebuilt and then just swap them out so I don't have any down time.

I put three because I figure with that much weight it will actually sag to two, but I could be wrong and I'll definitely do some research on compression ratios of specific springs.

I was planning on keeping a spare tire, clothes, tarps, perhaps some tools, and a couple jerry cans on the roof rack. would that be too much? I could also reinforce it by making blocks to go between the roof rack and the roof rails perhaps, then just put most of the weight on the front of the rack and the lighter things on the rear. Then I could keep the rest of the tools, spare parts, a jerry can, important documents, and whatever else inside and the second spare and another jerry can on the rear door. The biggest reason I don't want to put too much inside is so I wont have to move a ton of heavy supplies to the roof when I sleep in the back (which I won't do everywhere, just where it is safe enough to do so. Again, more research on specific places needs to be done.)

Are there any specific countries I should be aware of, or perhaps some way around that?

I do have dual batteries in the works. I've actually been working on designing a holder so that I can fit a couple pretty large AGMs.

I've never traveled outside the states, so thanks for the border cross warning.

I'll also check out those tires.

Thanks, very helpful!