tdi/LT77 conversion

Made a start on converting my S3 Lightweight, after some dicking around managed to get the TDI sitting in the engine bay, but when i went to pull the LT77 up to it it seems that theres not enough room between the bulkhead and the seatbox for the selector housing, meaning the transfer lever would be just inside the seatbox.
Its a normal defender (short) LT77 - does this box normally fit into a series 3 cab without hacking the seatbox, or has my engine somehow ended up too far forward?

Looking in the cab, the tdi flywheel housing is just touching the front of the large chassis crossmember under the bulkhead. (will try to get a picture up in a bit)

This is mine ...200Tdi and Lt77 in a S2a 88"



Have you sat the engine back to allow the intercooler to fit without cutting the fan off the waterpump ???

I've sat the tdi on the chassis mounts that were there. There was a transit diesel engine in there before, and the driver side mount has been modified, but it did not look as though it had been moved backwards or forwards. The other mount looks standard. I guess i need to measure up the mounts against a standard series 3 and check that first.

Transit sits a tad further back (or does in my Transit Di powered S3 88 ") i can see where the original mounts were trimmed off (Designa chassis galvy chassis)

You might need to reposition the Tdi to standard series position ...

mistericeman said:

Transit sits a tad further back (or does in my Transit Di powered S3 88 ") i can see where the original mounts were trimmed off (Designa chassis galvy chassis)

You might need to reposition the Tdi to standard series position ...

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yeah that was what was worrying me, that i would need to move the mounts and how the f*** would i know exactly where to move them to, with no engine or box in the truck to go by......

BTW, havn't you killed your di going through muddy water yet ?

Landy-ads said:

Made a start on converting my S3 Lightweight, after some dicking around managed to get the TDI sitting in the engine bay, but when i went to pull the LT77 up to it it seems that theres not enough room between the bulkhead and the seatbox for the selector housing, meaning the transfer lever would be just inside the seatbox.
Its a normal defender (short) LT77 - does this box normally fit into a series 3 cab without hacking the seatbox, or has my engine somehow ended up too far forward?

Looking in the cab, the tdi flywheel housing is just touching the front of the large chassis crossmember under the bulkhead. (will try to get a picture up in a bit)

Click to expand...

if it was me i do what i normally do fit defender seat box and tunnel ,fit gearbox to suit and then aline engine mounts like mistericeman has

Landy-ads said:

yeah that was what was worrying me, that i would need to move the mounts and how the f*** would i know exactly where to move them to, with no engine or box in the truck to go by......

BTW, havn't you killed your di going through muddy water yet ?

Click to expand...

No Trannie is still running fine (Well apart from the downpipe having rotted to death lol )

Best way would be bolting engine box together and slinging it into place and blocking it up whilst measuring .

Gearbox X member will need removing as it's in the way ...and Fan trimming from the nose shaft of the waterpump (best done with hacksaw as grinder CAN put too much heat into the shaft and fry the seals/bearings)

It's tight ...i recently swapped the box for a stronger LT77s and had to split the transfer box from the main box to have enough room to get the main box out due to the middle xmember .

All good fun though ...as IMHO the LT77 is far better suited to the Tdi (We run without an intercooler and have had no probs even on hot days towing a caravan ) AND are still on the standard series front axle ...bit snatchy at very low speed tight turns al la supermarket car park parking ...BUT normal use is fine and has been over the last 3 years or so .

OK cheers fellas, few options there. For a first stab I might just measure the position of the mounts on my mates standard s3 and then set about moving mine to the right position. Was wondering if it might be possible to have the engine abit further forward bthen standard so as to give the rear prop a bit more space - assuming the gear stick would not then end up too close to the bulkhead. There isn't much space in there.

jamesmartin said:

if it was me i do what i normally do fit defender seat box and tunnel ,fit gearbox to suit and then aline engine mounts like mistericeman has

Click to expand...

Btw whats the difference between defender and series seat box - is it just the shape of the tunnel opening?

I have the defender 200tdi tunnel and bulkhead diaphragm but not the seat box.

Landy-ads said:

Btw whats the difference between defender and series seat box - is it just the shape of the tunnel opening?

I have the defender 200tdi tunnel and bulkhead diaphragm but not the seat box.

Click to expand...

basically yes though battery/tool box is slighlty different