300TDi exhaust convert to ROW/latest spec

Well my exhaust rear section was worn out with a split running for 8 inches and further along another 10 inches so it was time for a replacement. The car was originally fitted with the standard exhaust which consists of the down pipe, mid section and end section.



Well I am looking at fitting a TD5 fuel tank later and also wanted a more straight forward setup so switched to the last spec 300TDi version.



The down pipe from the original spec exhaust is the same size and length as the last spec one so what you can do is start off with ESR2297 i.e. the down pipe without a cat then ESR4526 which is the last spec mid section and follow this with ESR4527

The front hanger of the mid section will fit normally but the rear hanger is in the wrong place. The rear hanger of the end pipe ESR4527 does not fit either BUT it can be made to fit by simple un bolting the hanger and fitting it the other way round.

So to convert you need {prices from brit-car}:

ESR2297 (if your down pipe needs changing) {£15}
ESR4526 {£32}
ESR4527 {£15}

At this moment in time I do not actually have a rear hanger on the mid box BUT a universal one for about £8 on ebay will do it. If someone has a ROW spec/98 spec diagram and can give me the part numbers we can see if that is better.

Very interested in doing this to mine, and getting rid of the rear in/out box, will you get photos up too?

I've got a mid-box, as above, from when I made my 300 Disco into a straight through with just the back box on, it was only on for about 6 months, but has stood around for a few years. If you're interested I'll check it and get pics tomorrow ..

I'll post images tomorrow. It's definitely an improvement and leaves the big gap between the rails where the TD5 rear tank goes.

Really keen on doing this!!!

Please keep us posted.

The brit-car section for the rear part of the exhaust is here:

Rear (2.5L 4 CYL TDI, '(-)90") | Defender 1983 To 2006 | Britcar (UK) Ltd

Can't work out which bits I need for the rear mount of the mid box but will have a look tomorrow with more light. Could do with an exploded diagram of the ROW spec exhaust system including hangers. The exhaust is all on and working and to be honest doesn't feel like it actually needs a 2nd hanger on the mid box but will look into it.

Pretty sure my 300tdi has another bracket for a hanger further back, but there is nothing bolted to it, will have a look tomorrow too. Is the big centre box a straight thru or is it more restrictive?

This is the current setup....

kes86 said:

Pretty sure my 300tdi has another bracket for a hanger further back, but there is nothing bolted to it, will have a look tomorrow too. Is the big centre box a straight thru or is it more restrictive?

Click to expand...

I think it's straight through but to be honest I didn't actually look!!

If you do have another bracket can you post an image?

centre box is straight through, a perforated pipe with sound deadening packed round it.

Rear bracket on chassis. In use.





Front bracket not in use but the hanger is there on the exhaust if I got a bracket for the chassis.

kes86 said:

Rear bracket on chassis. In use.


Front bracket not in use but the hanger is there on the exhaust if I got a bracket for the chassis.

Click to expand...

Do you have the standard exhaust system? Doesn't quite look like the ROW/final spec setup. My exhaust had another mounting like yours appears to have but it is in the wrong place. I will take some photos shortly.

Ok here are the pictures:


View from the side and rear






View of the final rubber mount (note that this DID point towards the side of the car but it has been removed and fixed back on pointing the other way. this moves the exhaust towards the centre of the car away from the tyre)




The exhaust then goes over the rear axle




We now get the the join between the rear section and the mid section/silencer (note that the existing hanger is too far forwards and the REAR hanger of the silencer is about 3-4 inches too far back. I have looked at this today and the easiest solution is a piece of metal about 5 inches long with two holes coming from the rear mount backwards. Not the ideal solution for strength but the exhaust feels totally stable and strong even without it so this will just be in addition)










Next we get to the front of the mid section/silencer and this fits onto the existing mount without any issues.

cowasaki said:

Do you have the standard exhaust system? Doesn't quite look like the ROW/final spec setup. My exhaust had another mounting like yours appears to have but it is in the wrong place. I will take some photos shortly.

Click to expand...

Yes I do, looking to change to later exhaust to get rid of back box.

I'll be doing this soon as my exhaust is shot,
I'll be putting the exhaust out of the crossmember so I need the mid box

Better late than never