ianmayco68

Cheers Bowie , so I can remove it then .

Oh no , when I’ve finished the 90 I’ve planned a refresh on the 110 , and I quite like the idea of a bmw m57 , seems to be a popular conversion.

Cheers Litch , there’s no actual wiring inside the box it’s just like a peg through the bell housing , so could it be an earthing point ? I remembered your thread about the conversion but last time I looked there were no photos because of photo bucket , looks a very smart truck . So that is the kick down cable , the bracket is a genuine Disco one so just need to find others who’ve done the conversion and find out if they’ve used one . The FIP pumps are the same so can’t see any reason why the Discovery bracket wouldn’t work . Have you got any photos of the FIP pump Litch so I can see how the kick down bracket fits on the pump please . cheers Ian

Looks like I’ve saved you some money , just seemed a shame to chop a perfectly good exhaust that someone could make use of when a rear box is only £30 .

Hi all , I'm rebuilding a 300tdi 90 and fitting a disco auto gearbox and I'm after a bit of help . Firstly what's this for it's on top of the auto box And secondly am I correct in thinking that this is the kick down cable , if so can I use it in the conversion as it's a Disco one or do I still need to buy the one's from Ashcroft's ? cheers Ian

Cheers Ed , thank you but seems a shame to cut a brand new one up when someone may be able to put it to better use , plus found quite a few on ebay stainless clamp on ones for about £30 , like this one . https://www.ebay.co.uk/itm/14-inch-Long-Stainless-steel-Universal-4-Exhaust-Silencer-Box-2-5-Inlet-63mm/352164917401?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3D18e4588e5e814487b82ce43809ad2572%26pid%3D100675%26rk%3D9%26rkt%3D15%26mehot%3Dag%26sd%3D382704160637%26itm%3D352164917401&_trksid=p2481888.c100675.m4236&_trkparms=pageci%3A2fc421c9-0eab-11e9-8ab1-74dbd180f859|parentrq%3A0f636f941680a9ca39265f52fff27094|iid%3A1 Cheers Jon , have already thought about those options , but as the pipe in the photo above is stainless and still in very good condition I was trying to save some pennies by re-using that and just fitting a back box to it .

I've been thinking about the exhaust for my 90 project which is a 300tdi but I've moved the fuel tank to the rear like on td5's so need a non standard one . This is what came off it It's a stainless steel jobbie and mated up to the standard 300tdi down pipe and if I can use this rather than buy a new one it would save some pennies , I've roughly test fitted the rear pipe today and it looks like it'll fit but as you can see it was a straight through exhaust and there's no back box . I can remember when the stepson had it fitted and it was load so does anyone know were I could get a stainless steel (preferably) back box so I can cut it and weld it back up . Cheers Ian

Thanks all for the input this is very interesting , when I did the 110 I just brought an Allisport front mount intercooler because I read they were better , but then after reading other posts on this subject I started to question it . I've had a good look at my standard intercooler today and its not good fins are crumbling when you rub your finger across them so I've got to buy a new one , but I did a bit measuring of the standard one can't remember the height and width but it was about 63mm deep and there were 17 rows of fins across which would mean the galleries would be pretty small as opposed to one of these off ebay . which has 11 rows. Or the one above which is a Direnza one which I'm thinking of trying as it's £150 as I've got to buy one anyway https://www.ebay.co.uk/itm/HIGH-FLOW-ALLOY-INTERCOOLER-FOR-LAND-ROVER-DISCOVERY-DEFENDER-300TDI-2-5-TURBO/232880361572?fits=Model%3ADefender&epid=22025976177&hash=item3638c05064:g:4WAAAMXQysxR781M:rk:26:pf:0 this one actually states a 1050cfm @ 0.5psi drop , is this good or bad ? I'm going to buy some of the thermocouples as well they're very cheap and when she's up and running I'll take some measurements , will do some on the 110 as well . cheers Ian

Happy New year to everyone .

I’d say just the seal and some grease , but as whoever checked them missed that I’d wipe the ball and check them just to be sure .

Thought it had , but sometimes photo's play tricks on you , the seal looks to be split there and further in on the ball . I think if you replace the seal it will be job done .

I'd say a new seal , the bottom left corner bout 8o'clock , the seal looks worn there as I think that's were the grease is coming from but it may just be how the photo has been taken.

Machine mart do some for £50 ish don’t know how good they are but there welding machines are reasonable.

A coat off the wife, which is what I’d asked for , money which will buy a swing away spare wheel carrier and some other stuff for the project and a genuine Land Rover mug off the step daughter which is very nice.

Did a bit more on this today as I needed to fit the newer td5 type wheel boxes before I sprayed the bulkhead , and to be fair it was a lot easier than I thought . Firstly opened the existing holes out to 12.5mm . Then using a steel deburer/rotary file bit in a battery drill opened out the hole to the correct shape . And voila it fits great . Got the bulkhead primered today and will finish spraying it tomorrow , so this part of the project should start to move along faster now .

I’d definitely do the wheel bearings at £20 aside it would be silly not too .

Merry Christmas all .

I rebuilt my transfer box last time but didn’t come across your problem but if you look on YouTube for paddocks Land Rover toolbox videos they will definitely help , the one below is part 1 of overhauling the centre diff . I can’t remember how I did mine now as it was my 1st one but I watched there videos and rebuilt mine it was very helpful. https://m.youtube.com/watch?v=vi5kHtvY-u8 hope this helps Ian

I quite agree , everybody’s knowledge and willingness to help is invaluable . Merry Christmas to everybody . Ian

Yes got the standard intercooler still . That’s exactly my thinking Ed , I think Daan’s test results proved that Land Rover actually did a good job with the results he got , his engine was standard I believe but there isn’t a vast difference between tweeked and standard , that’s why I was questioning whether a bigger intercooler was actually necessary given that a 300tdi is no race car , and would increasing the size of the pipe work and making the intake duct better be more beneficial . On snorkels Ed I was looking at vent turbos on turbo technics I think it was and they stated that there vent turbo shouldn’t be fitted if you have a snorkel fitted .

That's the plan Ed , engine's being totally rebuilt , fuel injection pump and injectors rebuilt by a diesel engineer friend asked him to tweak the pump when he calibrates it as he can set it up much better than I can , I need to replace the chra in the turbo as that was knackered anyway . The question about the intercooler was more whether a bigger one is really needed or do we fit them because were told there better , I started thinking about this after reading Daan's testing that he did . In theory we tweak the pump then throw a big intercooler on because that's what were told , there's no results published anywhere that backs up this , also I might be wrong in my thinking on this , but you tweak the pump which puts in more fuel which If my thinking's right means you need more air , so you fit a bigger intercooler which cools the air down lower and makes in denser , but I've not heard of anyone increasing the size of the intake pipes to feed the gigger intercooler or feed more air into the engine , so is a bigger intercooler actually worth spending £500 on ? Or would it be better to increase the pipe work to 3'' and run the standard intercooler ? I'm no expert on this and I could be talking total rubbish but after rebuilding the 110 , which was my 1st project and spending cash were I probably didn't need to because I was new to this and a bit naïve I've started reading up on stuff a lot more with this project and questioning whether parts we fit are useful or just there for the bling factor .

Having read your post and reading some other posts I agree with your thinking , I think a lot of the time we tend to believe what companies tell us even when there isn’t any data provided to back it up , the only data I’ve seen is what you provided which showed the standard intercooler to be pretty effective. The 300tdi 90 I’m rebuilding will become a daily driver while I want to improve it I’m looking to do it for as least as possible, at the end of the day it’s a Defender and I’m loathe to spend thousands to get it knicked . I’ve had the fip tuned up by 10% by the bloke who’s serviced the fip pump , the turbo had quite a lot of play in it so I’m replacing the chra with an upgraded one and was looking at improving the cooling the intercooler in the link is only £100 so not expensive but I might try what you did 1st , by changing the intercooler outlet and manifold inlet pipes to 3” . The thermocouples you used do you get the digital readouts with them when you buy them ? Just found them on eBay.

Not much done on this project as I've been trying to get the main project to the point were this becomes more easy , but hopefully by the time Christmas is over I'll be ready to push on with this . So as I couldn't get any old td5 wiper boxes I ordered some new ones of ebay , did a bit on it this morning prised the cog off the inside with a scraper which was pretty easy , I actually think the weak link in the wheel box is the cog and how it's mounted and when removed and an arm welded on I think they will last a hell of a lot longer , as all the knackered ones I've seen move pretty freely still . the holes in the bulkhead will need some opening out , well more elongating a small die grinder should work okay . And when I brought the disco 1 wiper mechanism I got the whole caboodle , so was thinking of using the frame and mounting the wheel boxes in this , a quick pic The motor bolts on to the frame and the arms will need cutting down so they fit , so in theory everything will bolt to the frame and then the wheel boxes will push through the bulkhead in the usual way and the 2 nuts will secure it , it might need some more bracing I'll post some better photo's up over Christmas when I've got all the other bits done

Cheers Snagger will have a go at balancing the pistons , found a video on youtube , seems quite easy to do just need a set of those small scales , not quite sure about drilling the insides of the pistons but must be safe as he was doing it . The intercooler above has 3'' inlet and outlet tubes so was thinking of making the inlet on the manifold bigger to match something that Dann mentioned in his testing , that the small outlet on the intercooler limited the flow .

If you're planning on having a go yourself watch these videos from Land Rover toolbox , videos explain it better than photo's . https://www.bing.com/videos/search?q=replacing+the+swivel+balls+on+a+defender&qpvt=replacing+the+swivel+balls+on+a+defender&view=detail&mid=FA3C2D49D696131BB849FA3C2D49D696131BB849&&FORM=VDRVRV There's quite a few , about 8 or 9 episodes explaining everything step by step .