Spent the last 3 days (25 hours) swapping out the old, swamp-water filled 1993 SWB RRC ZF transmission. The new trans came from a 1995 discovery and the fit was perfect. no issues on wiring or bolts.

Found and fixed a few other problems to boot:

1. RH (passenger) exhaust manifold rear stud had broken off (going into head). Also 2 studs ( 1 each side) on the exhaust flange to the downpipe had "snapped off" This makes a horrid ticking, loud exhaust sound and gets fumes/smell inside the rover. This bolt holds on an exhaust shield. new exhaust manifold-block and manifold-down pipe gaskets. With air tools and downpipe AND front drive shaft removed it only took 3 hours plus 2 trips to parts stores to accomplish.

2. downpipe - new O2 sensor. the left side 02 sensor was cut and replaced with one off ebay. Prior to installation I sprayed and blew out the new-to-me sensor with electical contact and switch cleaner. it
's like a NEW o2 sensor now. didn't mess with the other since the exhaust shop told me horror stories about old 02 sensors breaking or stripping out.

3. u-joints replaced. Took 3 hours to remove the drive-shafts (ft+rear) and only 20 minutes to reinstall. Had to break all bolts lose by hand -- and wised up to use air on reassembly. I WANT A good AIR COMPRESSOR and air tools now. the front shaft's in-board joint was toasted. upgraded to the new type with the zerk in the end of the cap. 005 ujoint for the front at autozone -- $14.88 each. carquest wanted $27ea -- same part.

4. rear trans seal on the Disco trans is RTC4650 it is the same part/size as the input seal for the transfer case. Dealer $17.88 bearing shop was only $4.88 but you need to take the old one there. I think it was a 42*62*8 -- but the size is written on the face of the seal -- it's not a mfg part number but the size!! Yes, I'm still learning.

5. cherry red heated and then pounded out the studs for the muffler. replaced with stainless so I can removed the downpipe more easily next time.


learned:

1/ there is a ground wire for the power windows gets corroded. my ground was bad and the windows worked intermittantly. --- it's the rear bolt for the center console. Bad design, just like the brilliant idea of putting a seat switch in a "catch all junk/spills/fluids" deisgn).

2/ you MUST stand the transmission on end (bellhouse UP) to properly install the torque convertor. it does go all the way IN when installing in the regular/Horizontal position.

3/ I love the way the disco transmission shifts and works . It's a big improvement.


pics -- will post if I learn how...

 

I haven't reattached the kickdown cable -- it seems to work better without. it...

 

If my wife weren't sleeping ten feet away, I'd be laughing out loud.

Nice job & post