Newbie needing help

[sopes]

Ok guys im abit stuck i have a 1985 90 2.5 diesel! engine is slugish, smokes like hell, got no 3rd and 4th gears, reserve keeps poping out all 4 wheel bearings are worn and shed loads of welding, so i got a small amout of work to do but do i get the box rebuilt and maybe buy a disco 200tdi and do a swap OR can i use the rear axle, gearbox+transferbox props and engine from a 92 disco tdi that i have been offered? and if that is possible is it a fairly straight forward swap or major headache.

Thanks

[western]

disco engine, axles & transfer box will swap over, main gearbox will need the gear lever mechanism swapping for the 90's existing one then it'll fit & be in the right place in the cab.

[sopes]

Ok great i just need to know if it was worth spending on an overhaul but as your reply il go for the disco swap.

Thanks for your help

[NicTheOrange90]

Whos to say that the 92 disco parts wont give up after all your work fitting them.

Give colin at CS gears in Coventry a ring, he can refurbish your gearboxes and diffs and thenyou only need to concentrate on the engine which could be re-built while boxes are out.

It would probably be less overall work and youd keep the same fittings as you have now, without trying to dispose of the Disco shell when you have finished.

[FridgeFreezer]

disco engine, axles & transfer box will swap over, main gearbox will need the gear lever mechanism swapping for the 90's existing one then it'll fit & be in the right place in the cab.

The gear lever mechanism can't be swapped without replacing the whole back of the box - ask me how I know

Disco tailhousing & shift mechanism:

Defender tailhousing & shift mechanism:

[sopes]

Hmm yes im confused so you chaps are telling me that the gearbox wont fit? but the engine and axle will! the reason that i want to change the rear axle is to have the disc brakes so i could still get the disco and use the parts i need and get the box recond, scraping the rest of the vehicle wont be a prob as i know the guys at the local breakers.

[JST]

what would i do, buy the 92 disco;

get the existing G box refurbished with Ashcrofts, In my opinion there is NO ONE ELSE to use. they know their stuff.

then fit the disco engine to 'refurbished' G box. Several guides here: Les/Dan/JST guide!!!

It doesn't sound like theres anything wrong with your existing T box so keep that unless you want the higher gearing (1.2) of a disco box for reduced revs at speed (it depends on the use of your vehicle as to whether is worth doing).

Front axle - change the wheel bearings or tighten them up as required and prob replace seals whilst you are in there if your is low mileage, if the disco has done less miles or had an easier life then fit the disco front axle.

Rear axle - i would fit the disco one as it has disc brakes and do the trailing arm bushes at the same time plus A frame ball joint and A frame Chassis mounting bushes.

Then get the welder out for the chassis (in fact you could start here whilst the G box is being exchanged.

Sell all the other bits off the disco. props, T box, front axle, etc etc

[sopes]

It doesn't sound like theres anything wrong with your existing T box so keep that unless you want the higher gearing (1.2) of a disco box for reduced revs at speed (it depends on the use of your vehicle as to whether is worth doing).

I will be using it to go to and from work (about 20min drive) and eventully would like to get into abit of offroading so what do you think would be best to keep the t box or swap with disco.

Thanks

[JST]

if you are doing alot of main road work and dont live in a too hilly a location (oops just seen your profile!) i was going to say like Devon or Somerset and dont do any towing then 1.2 is a good way to go.

if you tow or live in a hilly area then stick with 1.4 box.

Bear in mind that you can always change the T box later.

Off road isint affected, low is the same for disco and def box.

[sopes]

Ok mate thanks for your help