Workshop Projects
Standard Class Challenge Truck / Engine and gearbox
It was always the intention to use a tdi engine in the project vehicle, and a 300 tdi was the preferred option. An MOT failure Discovery arrived at a very fortuitous moment proved invaluable. The engine was sound and would make a fine donor.
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With the engine sourced, a gearbox was needed. At this point there were a number of options. We could source and R380 box from a Defender and build the vehicle as a 'standard' 300 Tdi Defender would be, we could use adapt the Discovery box, or graft the LT77 from the original Defender to the Discovery engine.
After much discussion, we chose to go for the latter option and mate the LT77 to the 300 Tdi. This would give us the LT77 selector layout which we preferred, and set the engine nicely back in the engine bay which would hopefully keep the vehicle well balanced.
Fitting the engine and box to each other was not going to be a direct bolt-on operation due to differences in the bolt pattern on the two units. The solution to the problem eventually proved to be quite straightforward. Because of the similarities between the Tdi block and the earlier engines, it was possible to remove the gearbox adaptor housing from the 300 tdi and replace it with the one from the Turbo diesel engine which had previously been removed from the 90. The addition of a small dowel to the block made the set-up a perfect fit and allowed us to mate the engine and box together properly.
With a new crankshaft oil seal and a new clutch kit, the engine and gearbox were bolted together. With this completed, it would now be possible to finish the chassis work and get it painted.
With the engine sourced, a gearbox was needed. At this point there were a number of options. We could source and R380 box from a Defender and build the vehicle as a 'standard' 300 Tdi Defender would be, we could use adapt the Discovery box, or graft the LT77 from the original Defender to the Discovery engine.
After much discussion, we chose to go for the latter option and mate the LT77 to the 300 Tdi. This would give us the LT77 selector layout which we preferred, and set the engine nicely back in the engine bay which would hopefully keep the vehicle well balanced.
Fitting the engine and box to each other was not going to be a direct bolt-on operation due to differences in the bolt pattern on the two units. The solution to the problem eventually proved to be quite straightforward. Because of the similarities between the Tdi block and the earlier engines, it was possible to remove the gearbox adaptor housing from the 300 tdi and replace it with the one from the Turbo diesel engine which had previously been removed from the 90. The addition of a small dowel to the block made the set-up a perfect fit and allowed us to mate the engine and box together properly.
With a new crankshaft oil seal and a new clutch kit, the engine and gearbox were bolted together. With this completed, it would now be possible to finish the chassis work and get it painted.
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