REKTS Disco 1 Daily / Restoration...

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REKT

REKT

Active Member
Posts
106
Location
Southend Essex
After cutting up my original disco to make a trayback project I never realized how much I'd miss greenlaning and general offroading as my daily, and basically not having to worry as much about exterior/interior of my disco 2.
So I scoured the popular sales sites and for a month found nothing that I liked the look of.. But then I stumbled across this on Sunday 22nd July and thought I'll have that no matter whats wrong as its got a fair few mods on it plus I feel like I should try and restore one rather than cut in half hahaha. But it was cheap at a price sub £800 so I expected the usual rust when I went to view it which I could tell it needed a boot floor and one body mount strengthening before it gets bad.

20180724_185801.jpg


But today I did have a look over it and never realized the boot was this bad but hey it was cheap and I've got spare sheet metal and know you can buy the boot floors online.
IMG-20180725-WA0007.jpeg
 
Your nuts. Why would someone do such a project... :eek::D

Will be watching with interest. Not telling you how to suck eggs but get the rear quarters off and check the a panels around the tubular cross member cos I bet if boots gone there are. Even my roof has rust o_O
 
Today has been a hell of a long day spent it getting the gearbox out in 30 degree heat with no airflow in the workshop haha, but its now out and I can see why it made a few rattles and the clutch just about gripped. Found out it was running a Borg and Beck clutch kit, as you'll see from following photos the s**t state it was in, has been fitted poorly as well the rear crank seal looked like it had been replaced ( forgot to get photos) but had been sealed on with some sort of instant gasket stuff in a tube and the flywheel bolts also had no loctite on them although they were bloody tough to get undone. So will be ordering a LOF Power clutch soon a long with various new seals and oils for the new gearbox/transfer box.
IMG-20180803-WA0002.jpeg


Here's the clutch friction plate that was slightly oily and had a cracked spring:
20180803_160356.jpg

Here's the flywheel that has some nasty looking cracks on it:
20180803_160403.jpg

Here's the bell housing that is lined with oil:
20180803_160922.jpg
 
REKT said:
Today has been a hell of a long day spent it getting the gearbox out in 30 degree heat with no airflow in the workshop haha, but its now out and I can see why it made a few rattles and the clutch just about gripped. Found out it was running a Borg and Beck clutch kit, as you'll see from following photos the s**t state it was in, has been fitted poorly as well the rear crank seal looked like it had been replaced ( forgot to get photos) but had been sealed on with some sort of instant gasket stuff in a tube and the flywheel bolts also had no loctite on them although they were bloody tough to get undone. So will be ordering a LOF Power clutch soon a long with various new seals and oils for the new gearbox/transfer box.
IMG-20180803-WA0002.jpeg


Here's the clutch friction plate that was slightly oily and had a cracked spring:
20180803_160356.jpg

Here's the flywheel that has some nasty looking cracks on it:
20180803_160403.jpg

Here's the bell housing that is lined with oil:
20180803_160922.jpg
Click to expand...

Flywheel might skim, if the gearbox isn't especially low then suspect the head gasket leaking at the back and infiltrating the bell housing, I think mine has done this and will need another clutch, again :(
 
dieseldog69 said:
Flywheel might skim, if the gearbox isn't especially low then suspect the head gasket leaking at the back and infiltrating the bell housing, I think mine has done this and will need another clutch, again :(
Click to expand...
Yeah I am wondering as its going to be so hard to trace due to there being so many other oil leaks I'm not 100% sure where its coming from :( but I hope its not the head as I've just ordered a LOF clutch and i dont really want to put that it with oil going on it
 
Start with rocker cover gasket but oil leaking from the head gasket is quite common, couple of hours work and less than £50 in a new Elring gasket and new bolts, it can't hurt as it's a good precaution fix that ensures you won't need to do it again any time soon.
 
dieseldog69 said:
Start with rocker cover gasket but oil leaking from the head gasket is quite common, couple of hours work and less than £50 in a new Elring gasket and new bolts, it can't hurt as it's a good precaution fix that ensures you won't need to do it again any time soon.
Click to expand...
Yeah I'm going to change the breather unit as that looks like its leaking and clean up the engine so I can try see where its coming from :)
 
Some good news the big order went in this weekend!
- LOF Power clutch
- Rear crank seal / gasket
- Cyclone breather filter
- Timing belt kit
- r380 Gearbox input and output seals
- LT230 seal kit
- Few tools from machine mart
- Oil / Filters / brake cleaner
- Clutch slave cylinder
- Rocker cover gasket
- Crank seals

So over the next week or so expect some updates hahaha
 
What belt kit did you go for? I've read that some 300tdi have a faulty alignment that makes belt shred and that you need to upgrade but couldn't work out what kit is required
 
resto_d1 said:
What belt kit did you go for? I've read that some 300tdi have a faulty alignment that makes belt shred and that you need to upgrade but couldn't work out what kit is required
Click to expand...
they did when they first came out several mods were made, one was rear injection pump bracket fastening and another the crank pulley was given guide lips instead of the tensioner pulley,you just ensure now you have the right crank and tensioner pulley fitted as below
shopping

shopping
 
resto_d1 said:
Someone got paid this weekend :D

Good graft put in there! I'll be doing a clutch etc when I get mine on the road in 2087 o_O
Click to expand...

resto_d1 said:
What belt kit did you go for? I've read that some 300tdi have a faulty alignment that makes belt shred and that you need to upgrade but couldn't work out what kit is required
Click to expand...

I just bought the same one I fitted on my offroader...STC4096L
Should be right I hope xD
 
So Tuesday my LOF clutch arrived thought I'd take a few comparison photos, just incase anyone else was looking to upgrade!
20180815_192653.jpg

20180815_192218.jpg

20180815_192233.jpg
 
The new clutch and better condition flywheel has been fitted but now I'm waiting on a gearbox to be removed from a local parts disco to fit onto mine.
20180830_202019.jpg

IMG_20180830_233303_306.jpg

IMG_20180830_233303_309.jpg
 
Whilst at the LRO show I was drawn into the Fourby tent and picked up a fair few little bits that will truly test the new clutch out.
-EGR temp gauge kit / 3d printed holder that replaces the clock / temp probe threaded plate
- Boost pin
- Dynamic timing ring
- Boost controller
20180917_150306.jpg
 
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