2002Discovery 2 v8 manual conversion

Hi all,
Will be keeping my progress on this logged here for anyone who interested or doing a similar thing to theirs.

So as the title suggests I'm converting my Land Rover discovery 2 v8 (black disco see photo)to manual. Always prefer the manuals and I think the auto in mine is beginning to go south anyway.

I managed to find a donor discovery 2 (blue disco in photos) with only 73000 miles on it with terminal chassis rot. This will be what I take the majority of the parts from and what i reference to. At the moment I am removing parts required from the donor vehicle and getting ready for the big swap over in a few weeks over the time off I have around Christmas.

In short the plan is to.
-remove all parts required from donor discovery.
-remove auto gearbox and associated parts from my discovery
-install all manual associated parts into my discovery and get it mechanically working.
-lastly concentrate on getting the computers happy.


I look forward to hearing from you guys and your support will be invaluable.

P.s I'm new to the forum and am not sure how to put photos in. If it helps I'm posting using an I phone.

Thanks a lot
Tony

Sounds interesting, keep us updated

Yep I plan to do it completely over the Christmas period as I'm off. I have removed; gearbox, flywheel, clutch, master cylinder, slave cylinder, hydraulic clutch line and pedal box. Will be reinstating difflock using a d1 linkage too.

Cheers for your support!

Today is the day I hopefully get round to taking the automatic parts off of my discovery. Weather permitting obviously.

Right it's been a tough few days but it's complete!
Haven't driven it yet though as its got a flat battery, it wouldn't jump and my battery charger is with a mate... typical! Here are some pics from the project.

Stripping of the interior

Automatic transmission tunnel cover, differs to the manual version.

Transmission cover plate removed, makes it easy to get to the top transfer box bolt and nut.


Automatic transmission cooler removed. Brand new manual version going in its place from Land Rover, new oil cooler lines as the one from the doner vehicle didn't look great. Obsolete parts only 2 of each pipe in Europe had to order from Austria!

The strip down underneath begins. Props, cross members and exhaust removed.


Better picture than last.



The offending automatic gearbox, transfer box already removed at this point.


Garage in a right state!!!



Flex plate in terrible condition big cracks all around where where the crank bolts and cracks going from the centre outwards. Not a moment too soon!

Flywheel and flexplate removed.

Crank sensors,
Left manual, right automatic. Same sensor shorter spacer on the manual worth noting if was left as is probaly wouldn't start.



Automatic pedal box removed.



Rubbish picture of flywheel installed.




The above picture is a link wire that was plugged into the main loom. I removed this and pulled the corresponding plug out of the loom above the pedals. This plugs straight into the clutch switch, this should enable the clutch to deactivate the cruise control pressed.


Clutch installed. Using old one as looked like new and the engine will be swapped out for one I'm building in the near future. Something worth noting is that when the flexplate was removed there was already a spigot bush in the crank. I removed this as I didn't like the look of it. Probably just me being over cautious.


Manual pedal box and clutch master cylinder installed.

Gearbox already installed and transfer box with diff lock going in. I used a discovery 1 turret and linkage to activate it.


Discovery 1 turret and difflock.



Transfer box and gearbox installed and on the mounts.


Discovery 2 manual transmission tunnel cover plate with hole cut to accommodate discovery 1 difflock. Won't be the final product as it is not sealed from the outside elements. The discovery 1 has a cover that's made of rubber not steel and should fit the disco 2 with the disco 1 turret and diff lock lever.

How the 2 centre consoles differ. Left is manual and right is auto (mine)

If you look closely the both have a casting line around the gear Selector. I used this and cut the one out of the manual console and cut the hole in mine to accept the piece from the manual console. I then plastic welded it. It will all be covered by the rubber mat.



Final results! After a test drive tomorrow I will know how it all is. I need to reprogram bcu and possible replace the ecu. Will do that tomorrow also.

I would have liked some more pictures but carrying this out on my own has made it difficult. If anyone has any questions I will be more than happy to help. Thanks for reading!

All is well after a test drive done 25 miles or so. Only issue I have now is warning lights and fault codes which is to be expected. I need to swap in the ecu I have from the donor vehicle and have it programmed. I need test book for that. Anybody has it and are willing to help I would be very thankful. Maybe I can help you I have an array of
Landrover parts, breaking a d2 and I have some d1 parts.

Hi, my partner had just bought a donor disco 2 to convert his from auto to manual, we’ve been told loads of different things as to what needs to be changed over etc. Was wondering if it’s possible for you to give a list of everything you changed, out of hours of searching your post is the only one I found that helps can’t seem to find any other help on what needs to be changed seems to be a non existent thing people changing from auto to manual
Thanks.