I have the front drive shaft! Will install this weekend along with rerouting the exhaust. This was made necessary because of the Transfer Case swap.
Ready to put this beast back on the road.

 

This is not my final post on this project, but it nears completion.
My 2000 Disco II is running and driving with a 2004 GMC LM4 5.3 Liter truck engine. This is an all aluminum LS family engine. It puts out around 285 - 295 HP. For reference, this is the same block and heads installed in the Chevrolet SSR retro trucks. The only modifications I made to the engine for installation are: the driver side exhaust manifold was swapped for an F-Body unit and heavily modified to clear the frame rail. And, the oil pan was swapped for a GM performance parts LS-Swap oil pan. I purchased an aftermarket air filter and intake tube designed for full size Chevy pickups. Also, the purge solenoid was removed and plugged only because it would not clear the hood. The GMC power steering pump had to be relocated up higher to clear the Rover steering gear.
Motor mounts as well as transmission cross member mount are custom built.


I am using the 4WD 4L60E transmission from the donor GMC. I am also using a full time AWD transfer case from a 2002 Yukon Denali. The TC is clocked about 160 deg ccw and currently only four of the six bolts are installed. (the other two will require some modifications)


The drive shafts are custom made. The rear diff yoke has been converted to the 4- hole flange (Rotoflex eliminator) Both front and rear 4-hole flanges now use standard u-joints rather than the stock metric ones.


I feel I am over the hump now and this conversion WILL work. The biggest question I still have is whether the TC will last running upside down. I have adjusted the oil quantity in the unit up to at least 1 extra quart. With only the recommended amount, it was very noisy.


The short list of things left to do:


1. Install back-up light system.
2. Install new vent on the TC, plug old vent.
3. Install new seal in rear yoke. (got trashed because of malfunction explained below)
4. Finish custom engine cover.
5. Clean up wiring add some straps and loom.
6. Modify plastic trim panel on back side of center console (floor was clearanced for transmission)
7. Modify shifter linkage so console markings line up in proper positions.
8. Add some kind of transmission position indicator.
9. Need a parking brake, but I don't see that happening easily.
10. Figure out how to make speedometer work correctly. (I think the ppm is incorrect)
11. Install AC lines, recharge and test system.


.... And a lot more, some not related to the swap.


A few pictures attached.


Notice the difference in the stock yoke and the Rotoflex eliminator yoke.


I had to add on to the length of the yoke to get any preload at all, it was at least 1/2" short. Maybe they sent me the wrong one, or maybe others have had this same problem?
I installed the yoke without realizing it was incorrect, and it came loose and trashed the seal, made a heck of a racket too.

 

Just wow..

 

Sorry for lack of pictures lately, I know a build thread without pictures is USELESS!!!
Here are some drive shaft and transmission mount mods.

 

Notice the half moon notch in the cross member shown above. This was necessary to clear the front drive shaft. Also, the cut away in the transmission mount was needed to clear the exhaust. Probably will have to completely rework the exhaust at some point. The original design and install was for the first TC I used which ended in failure. The second TC is way different and clocked in a better position, so now everything is in the way of each other. I temporarily installed some flex exhaust tube to get the truck going quickly.


Shown below is also a picture of the rear high angle u-joint which as it turns out was not high angle enough. I had to clearance it some to keep it out of a bind.

 

For the Rover purest among you who might think this entire ordeal an exercise in blasphemy, I do understand your point. However, I would like you to think of the vehicle in a different light. If I had not decided to do this swap, the truck would almost certainly have wound up crushed at the salvage yard. My feeble efforts have breathed new life into the vehicle and it may be on the road (or trails) for at least a few more miles.


Thanks for your help, support and understanding.

 

Screw them.. This is awesome. I would love an ls powered rover.

 

Blasphemy is selling a truck powered by a 40 year old engine design that has been bored and stroked well beyond any prudent limits, poorly assembled and then made to run about 30 degrees hotter than it should. All for about the highest sticker price in its vehicle segment. Quite the project. I would consider trying to mate a slightly smaller displacement engine to the ZF tranny and control it all with the stock motronic system but I would never attempt a wholesale swap like you did. Very impressive.

 

Thanks!
Just doing my part to save old cars from the crushers one at a time!

 

brother, of all the things I enjoy about these trucks...... the feeble excuse for a power plant, is not one of them. imo, no harm in doing a engine-ectomy and swap on a disco.....never heard anyone screaming in excitement about putting a bone stock replacement in their disco. I appreciate your efforts and documentation of the swap.