Hello everyone.

That's it: here we go

old engine removed, 300tdi+ disco GBoxes hanging in the empty hole from a crane as of today.
I have got a couple of issues for which I'd like to know how some of you solved them.

1. alternator in the way of the left top shock mount (or the other way around, rather). Did you cut away part of the old shock mount to make it fit? If you did, do you have any pictures of that? I thought maybe to move the front and rear shock mounts altogether to permit the installation of standard defender shocks (not shitpart ones though - proper ones)... has anyone done that? If yes: where did you put the new mounts?
2. Engine sump and fron diff: fram what I can see, these two come very close, if font suspension fully compressed. Did you leave the engine in the "sefender" position (left/right wise), or did you slightly move it to the left?
3. gearbox height: the LT230 gearbox mounts are much lower than the ones for the LT95. Who can show me some photos of their mounting brackets, to give me some ideas?

... (many) more questions to come

Thanks in advance

Oliver

My Borg warner has a piece of 10mm flat plate as a left hand mount. With the V8 and auto box on standard mounts it's a straight line from the mounting up to the standard 101 chassis mount.

The right hand one has a leg extended backwards and down from the mount in 10x50mm
this supports the standard rangie right hand mount.
Works for me anyways.

I'll take some photos when I see the truck in daylight next.

Das: photos would be VERY HIGHLY appreciated, thanks in advance !

I have a 200tdi dropped into mine, didn't fit it originally so have no idea about shock mount issues. but if i get home in time tomorrow i will take some pics of how my lt230 is mounted into the chassis if it is of any use to you?

Definitely !!!!
Regarding the alternator this is a purely 300tdi issue as the alternator is mouted very low and very outboard on the left side. I even thought about moving it to the top of the engine (where the aircon compressor normally goes) but it would need a custom-made bracket with the risk of belt alignment problems. Plus if I have to fabricate an extra bracket, might as well be the one for the shock absorber ... plus I intend to fit an aircon compressor in that location to generate compressed air, so I'd really like to avoid that solution ...

Not sure how much help this will be! I have a 200tdi disco lump in mine ,when i first put it in the sump was quite close to the original prop, so close that i ended up taking it off in Morocco and getting the return pipe moved to the rear right chamfered side and the front rhs corner heated and hammered in and braised for more clearance . This was close due to the extra weight of the diesel lump, it has extra leaves on the front now too.
I'm quite sure that the lt230 sits lower in the chassis than the lt95 but it should get rid of the prop rumble ,i've never had any ground clearance issues and mines been in since 2001.
I used the the original engine chassis mounts and modified disco engine mounts this put the brake drum about 2" away from the cross member and made new gearbox mounts.
The engine and box sit slightly tilted down at the back eg. the rocker cover is closer to the chassis at the back end.

would have to check, but i think motor and diesel sell a modified sump to give extra clearence on the prop using a tdi300

my hs2.8 conversion required a holt cut in the side access hatch to give alternator clearence, but nothing more - check yours - it may be very close but ok.

(the hs was ment to be an 'easy' replacement for the 300, so a lot is the same)

used a bell housing from zeus with original gearbox. i dont think the gearbox position changed.

intercooler from alisport mounted in front of the radiator
my radiator was no good anyway, so a new one fitted, with electric fan

(i didnt personally do the work, and it was a while back, but can try and check details for you)

Hi Oliver,

Sorry was dark by the time i got home on Monday night.

LHS gearbox/transfercase mount from above


LHS mount from below:


LHS mount


RHS mount, bolted to chassis just behind original mount.


RHS mount

Sorry Phil but those mounts are not really upto the job,and are probably the cause of that split rubber mount on the lhs. I'd be inclined to get some better ones fabricated and a new rubber mount fitted before your gearbox ends up scraping the road and your engine tilt causing your fan to eat the radiator core.

LHS is not ideal agreed, still a work in progress. The rad is safe though, got a kenlow fan have been looking at that mount going hmmm not ideal, will get something sorted as it would be a pain if it falls off!

Hi Phil, on The Yellow Elephant my mounts are very similar in designto yours, however since first putting the 200tdi i have had 3 different gearbox mounts .
The first one on the overland was done in a hurry but was as strong as hell it was made from 2x1" steel in a big "U" shape using original disco mounting rubber in the centre and bolted to each chassis rail, only problem was it was a bit low to the ground but never hit though!!
The second one, on the lhs was a flat plate 5mm thick with a piece of 1x1/8" flat on either side pretty strong you would think but it started to bend!!
The third has now been changed for 8mm plate, it's ok now .On the rhs its only 5mm plate but as its so short it is still fine but it does have 2 rubber mounts as it takes most of the weight.
From the photo the lhs one doesn't look quite the right angle, I don't want to tell you how to suck egg, but i didn't bend mine but made them out of 3 pieces 2 triangle and one square you can line it up and tack it to get the perfect angle ,then weld fully.
Hope this helps if you have any other questions will try to help!

Phil and Jon,
you have to remember that the rubber mounts are supposed to be under a perpendicular (static) effort only, or compression effort. Any gearbox brackets that are flexible in only the slightest way, will induce a shearing effort, which the rubber mounts are not designed to withstand. If my engine was held in such a manner, I'd definitely strap a strong cable or belt underneath in case the rubbers shear off.

At least, Phil's picturs do confirm that my gearbox position is about the same and show the general geometry of what's needed.

To enable me to design my mounts I have suspended the assembly from a hoist, and all is adjustable in all angles (original radiator removed since that photo was taken)



Julian, on this photo you can see why I mention the left shock absorber support, which is in the way of the alternator (the alternator goes into that casting's big hole)



Moving more to the left would cause the alternator to touch the chassis rail, more to the right and it's the oil sump which comes in the way of the front diff. Julian I'll remember about the possibility to modify the sump in case it is needed, I have a spare one.

I'll photograph mine at the weekend. Not likely to be able to get to it before then.
It's been at my mums since the exhaust collapsed last week.

Looks like a squeeze I'm now thinking that the Disco 200tdi is the best bet with a non standard 101 gearbox !!!

in my ambi i used the gearbox cross member from disco and ground off old mounts fits like a glove

Is that not really low ?

its a smidge low but cant see it grounding out on anything its a fair bit higher than the diffs