R380 gearbox and 300TDI engine in to a 90? Possible?

Hi Guys

I have 2.5 NA 90 G reg and bought a R380 gearbox and 300TDI engine from a Disc N reg.

I have mounted the LT77 gear selector to the R380 gearbox so it sits in the right position.

1. Will the R380 Gearbox fit in to a defender 90
2. For the 300TDI engine I am welding new engine mounts on etc
3. Any tips advice etc?

I think I had a problem with the exhaust coming down right where the engine mounting was, Mine was a G reg 90 as well.
I used a modified Disco mounting plate to bolt engine to and then the mounts to rather than move the mounts, engine is about 4 inch further forward so all the hoses etc fit ok
Gearbox is the same, it's a bit closer to the seatbox but not a problem, mountings and props fit ok
I ended up swapping the 300 back for a 200 as I had problems with the engine

The R380 is what was fitted to 90's and 110's when the 300tdi defender came out, most notable difference is the engine is mounted further forward than in previous models. Many of the cable/ oil pipes ect are different lengths/ shapes. Some of these you may be able to source from the Disco or just purchase new.

R380 in chassis with 200tdi

I fitted 300tdi and r380 disco engine into my V8 90 years ago. Seem to remember I had to make up a new gearbox mount as I think they are mounted on the crossmember on a disco (not 100% sure). You will have to drill and tap the transfer box to fit the handbrake bracket (easy enough).
Make sure you mount the transfer box so the propshafts have the same amount of travel on the splines.
Didn't find it too difficult to do to be honest. Worst bit was making the exhaust as I didn't cut the engine mounts off the chassis as it was a galv one (didn't want it to rust), so the engine mount ended up underneath the manifold flange.

If you want the 300tdi in the factory position, you need to mount the transfer box 2-inches further forward than the 2.5N/A.
Use the Discovery gearbox cross-member and front prop, and copy the Discovery engine mounts. You don't retain the 2.5N/A bolt in cross-member. You will need a 300tdi rear prop and a 300tdi transmission tunnel. The front of the seat box will need slight mods.
If you do this then you can use standard 300tdi Discovery/Defender exhaust pipe, rad and PAS pipes etc.

Fantastic Guys...

The current exhaust is for the 2.5 NA engine, will this be comptiable with the 300TDI engine, im thinking im running higher BHP and its Turbo charged engine rather then NA,

Would I need to modify the exhaust for the engine to 'breath' better??

Simple answer is no, not suitable.

Could I modify the existing exhaust?

You could modify to fit but not worth the trouble and it will not "breath" as well as a proper 300 system.

You will need a 300tdi front section, the middle and rear sections are far too small. As full 300 exhaust is the only real option, although you may need to modify the mounting brackets.

I just clarify that the R380 and 300 TDI are from a disc 1996?
Believe the R380 wont fit due to longer bell housing and I need a 'stumpy' short bell housing?

Adam786 said:

I just clarify that the R380 and 300 TDI are from a disc 1996?
Believe the R380 wont fit due to longer bell housing and I need a 'stumpy' short bell housing?

Click to expand...

No, you use the stumpy bellhousing to fit the R380 to a pre-300tdi 4-cylinder 90/110.
The 300tdi bellhousing is the same on Defender and Discovery. In STANDARD 300tdi installation, the engine is 6 inches further forward than earlier models.
You could use the stumpy bellhousing, and you would not need to move the transfer box or swap propshafts, but it would put the engine in a non-standard position which would require other modifications.

Thanks RR, What would you suggest would be the easier way of doing it?
1. Keep the standard set up or install a stumpy?
2. R380- gearbox mounts- Do I need the R380 cross member to fit?
3. Im thinking I have a LT77 gearbox laying around- I may make my life easier and install that which was originally installed in it and mount the 300TDI to that instead?

Adam786 said:

Thanks RR, What would you suggest would be the easier way of doing it?
1. Keep the standard set up or install a stumpy?
2. R380- gearbox mounts- Do I need the R380 cross member to fit?
3. Im thinking I have a LT77 gearbox laying around- I may make my life easier and install that which was originally installed in it and mount the 300TDI to that instead?

Click to expand...

I would use whichever is the best gearbox. You can fit the 300tdi to your existing gearbox, but you have to get new engine mounts, modify the exhaust and some of the coolant and PAS pipes. Google Glencoyne Engineering, they have plenty of information.