Disco 2 Problem fitting genuine LR battery

Keith_L · Jul 3, 2021

The battery in my Discovery 2 is on its last legs and I ordered a new one from Land Rover. Based on the VIN they supplied part number LR135238 which superceded YGD100860. However, the height to the flat top where the clamp goes is 8.5" (216mm), whereas the one I have is only 8" (203mm). It is a struggle to fit the clamp with the existing battery and tighten the wing nuts so it will be impossible for the new one. The front screw is a 'J' hook which could probably be replaced with a longer one, but the back seems to be a rod attached to the base of the battery box.

What's gone wrong?

Keith_L · Jul 3, 2021

I think I may have worked out what is going on. I think both the threaded rod at the back of the battery and the 'J' hook at the front have been sawn off for some inexplicable reason.

Back to eBay.....

Stanleysteamer · Jul 3, 2021

Just buy yourself some threaded bar and cut it to length, bend it up where you need to.
Not difficult.

EDIT
As for the rear one, it ought to be possible to get to the underside of the batt box and use two nuts to make a lock nut if there isn't a captive nut. And if there is then just use your two nuts to make a lock nut so you can use it to screw the threaded bar into the captive nut.
All this said with no prior knowledge of the exact situation, just applying old skool common sense.

Andy Warren · Jul 3, 2021

Keith_L said:
The battery in my Discovery 2 is on its last legs and I ordered a new one from Land Rover. Based on the VIN they supplied part number LR135238 which superceded YGD100860. However, the height to the flat top where the clamp goes is 8.5" (216mm), whereas the one I have is only 8" (203mm). It is a struggle to fit the clamp with the existing battery and tighten the wing nuts so it will be impossible for the new one. The front screw is a 'J' hook which could probably be replaced with a longer one, but the back seems to be a rod attached to the base of the battery box.

What's gone wrong?

Hi, that battery looks too small for the TD5, I see the long clamp bolt is now discontinued but the 'J' one is still available, I'll take some pics of mine tomorrow along side a rule so you know how long they should be.

Keith_L · Jul 4, 2021

Thanks guys.

The old battery is far too small, physically and electrically. It's only 72Ah and 480A as opposed to the 105Ah and 800A of the new one. If you could measure the length of your rod and 'J' hook it would confirm if my suspicions are correct.

From looking at the parts diagram on Land Rover Classic I think the rod at the back just screws into a captive nut - no other parts are listed. I put some easing oil on last night to help removal and just hope the end hasn't been peined over or the rod doesn't snap off in the hole. I did think of getting a length of 6mm studding and making my own, at least for the back rod.

Andy Warren · Jul 4, 2021

Hi, here's the pics of my battery clamp fixings. As you can see the threaded bit sticks out 20mm above the nyloc nuts once the battery is clamped in place so yours as you say have been cut down. Hope this helps. Pic 2 is the rear stud 245mm from the inner wing so you will have to about 20mm to that to screw into the wing.

Keith_L · Jul 4, 2021

Thank you @Andy Warren. Those lengths tally almost exactly with what I calculated they needed to be to do the job properly. I'm impressed by your Nyloc nuts - I've got a couple of rusty wing nuts and washers. You also seem to have some plastic trim along the front that I don't, as well as a piece of rubber by the front 'J' bolt. Interesting. You do start to wonder what else is wrong with/missing from my Discovery.......

On the plus side your clamp is the same way up as mine so that's good.

Thanks again.

Andy Warren · Jul 4, 2021

Keith_L said:
Thank you @Andy Warren. Those lengths tally almost exactly with what I calculated they needed to be to do the job properly. I'm impressed by your Nyloc nuts - I've got a couple of rusty wing nuts and washers. You also seem to have some plastic trim along the front that I don't, as well as a piece of rubber by the front 'J' bolt. Interesting. You do start to wonder what else is wrong with/missing from my Discovery.......

On the plus side your clamp is the same way up as mine so that's good.

Thanks again.

Your welcome, the plastic cover only clips in & the clips break easily so I guess they get thrown away & that piece of rubber isn't glued in position (must do that tomorrow). As it's only had one owner from new & by his own admission knew nothing about cars, he never mucked about with anything which is just as well as LR built in enough of their own problems for us owners to deal with

.

Keith_L · Jul 5, 2021

I take it the bit of rubber is your addition?

I don't suppose you would be good enough to take a photo of the plastic cover at the front and I will see if I can find one at a breakers.

Many thanks.

Andy Warren · Jul 5, 2021

Keith_L said:
I take it the bit of rubber is your addition?

I don't suppose you would be good enough to take a photo of the plastic cover at the front and I will see if I can find one at a breakers.

Many thanks.

Hi, pics attached. There should be l/h & r/h covers I've turned them over as they have the p/no's on them. The rubber is original as far as I know although it doesn't appear on the p/list.

Keith_L · Jul 5, 2021

That's absolutely brilliant of you Andy - thank you.

Stanleysteamer · Jul 5, 2021

Andy Warren said:
Hi, pics attached. There should be l/h & r/h covers I've turned them over as they have the p/no's on them. The rubber is original as far as I know although it doesn't appear on the p/list.

Blast! I'll have to go and look at mine now to see if they are missing or not!

Keith_L · Jul 5, 2021

I took another look at mine and it's different to yours. Is yours pre-face lift?

Andy Warren · Jul 5, 2021

Keith_L said:
I took another look at mine and it's different to yours. Is yours pre-face lift?

Yes it is MY2001, that's why there's a difference so I don't think anything's missing.

Keith_L · Jul 5, 2021

Thanks Andy. Those two bits may not be missing but when I was taking the photo I noticed the rubber along the driver side of the engine bay is missing....

Andy Warren · Jul 5, 2021

Keith_L said:
Thanks Andy. Those two bits may not be missing but when I was taking the photo I noticed the rubber along the driver side of the engine bay is missing....

Ah you have one rubber strip missing (mine has both), they are still available CJE100820 £14.75 inc. quite reasonable for LR

Keith_L · Aug 1, 2021

An update. Two rubber strips sourced and installed either side of the engine bay.

Battery-wise everything is as @Andy Warren and @Stanleysteamer both said. I sourced a rod and a 'J' hook but unfortunately I ran out of PlusGas and time as I needed to use the car so didn't manage to get the back rod out. The rod is turning in its captive nut okay but the nut holding the bracket on is rusted solid and won't shift and I'm starting to round it off. Instead I improvised and used some studding and a stud extender to lengthen the existing rod. I was then able to fit the new battery. When I have a bit more time I will get down there with the PlusGas and do the job properly and replace the back rod. I also took the opportunity to clean up the engine bay and battery box a bit so everything looks much better.

Thank you both for your help.

Stanleysteamer · Aug 1, 2021

Keith_L said:
An update. Two rubber strips sourced and installed either side of the engine bay.

Battery-wise everything is as @Andy Warren and @Stanleysteamer both said. I sourced a rod and a 'J' hook but unfortunately I ran out of PlusGas and time as I needed to use the car so didn't manage to get the back rod out. The rod is turning in its captive nut okay but the nut holding the bracket on is rusted solid and won't shift and I'm starting to round it off. Instead I improvised and used some studding and a stud extender to lengthen the existing rod. I was then able to fit the new battery. When I have a bit more time I will get down there with the PlusGas and do the job properly and replace the back rod. I also took the opportunity to clean up the engine bay and battery box a bit so everything looks much better.

Thank you both for your help.

First of all, no need to thank us, although it is nice to be thanked BUT also, you won't believe this but you have helped me!
That nut you put up in the second pic I now realise is one I was trying to undo when trying to take the inner wheel arch protector off to fix my foglight!
Now I know what it connects to I will find it easier when I come to do the job properly.
I just looked at it and thought, "Oh fuck I'll have to take the batt out, it must be somewhere under all that crap, etc, cant be fecked!"
What luck!
Ta again mate!

Andy Warren · Aug 1, 2021

Keith_L said:
An update. Two rubber strips sourced and installed either side of the engine bay.

Battery-wise everything is as @Andy Warren and @Stanleysteamer both said. I sourced a rod and a 'J' hook but unfortunately I ran out of PlusGas and time as I needed to use the car so didn't manage to get the back rod out. The rod is turning in its captive nut okay but the nut holding the bracket on is rusted solid and won't shift and I'm starting to round it off. Instead I improvised and used some studding and a stud extender to lengthen the existing rod. I was then able to fit the new battery. When I have a bit more time I will get down there with the PlusGas and do the job properly and replace the back rod. I also took the opportunity to clean up the engine bay and battery box a bit so everything looks much better.

Thank you both for your help.

Nice job, I had to clean all that area

Keith_L said:
An update. Two rubber strips sourced and installed either side of the engine bay.

Battery-wise everything is as @Andy Warren and @Stanleysteamer both said. I sourced a rod and a 'J' hook but unfortunately I ran out of PlusGas and time as I needed to use the car so didn't manage to get the back rod out. The rod is turning in its captive nut okay but the nut holding the bracket on is rusted solid and won't shift and I'm starting to round it off. Instead I improvised and used some studding and a stud extender to lengthen the existing rod. I was then able to fit the new battery. When I have a bit more time I will get down there with the PlusGas and do the job properly and replace the back rod. I also took the opportunity to clean up the engine bay and battery box a bit so everything looks much better.

Thank you both for your help.

Nice job, I had to take the battery box out when I first got it to clean all the oil that had leaked out of the injector loom, which I still can't believe.

Keith_L said:
An update. Two rubber strips sourced and installed either side of the engine bay.

Battery-wise everything is as @Andy Warren and @Stanleysteamer both said. I sourced a rod and a 'J' hook but unfortunately I ran out of PlusGas and time as I needed to use the car so didn't manage to get the back rod out. The rod is turning in its captive nut okay but the nut holding the bracket on is rusted solid and won't shift and I'm starting to round it off. Instead I improvised and used some studding and a stud extender to lengthen the existing rod. I was then able to fit the new battery. When I have a bit more time I will get down there with the PlusGas and do the job properly and replace the back rod. I also took the opportunity to clean up the engine bay and battery box a bit so everything looks much better.

Thank you both for your help.

Disco 2 Problem fitting genuine LR battery

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