Project disci daily driver and green lane

Hello all , so after various questions I thought I should start a progress thread off and what intentions I have got for my D2.

Well it's going to be a daily drive and a green laner . I only work 20 minutes on a bad day from home and I dont drive far often . My other hobbies are hill and mountain walking , amateur radio along with CB. I end up going playing radio on hills etc . So will be adapted for that use along with camping also .

Right here she is ...



Excuse photo bucket logos I'm not sure how to remove them ...

Well on Saturday I replaced water pump , serpentine belt , checked idlers and tensioner , replace both engine filters and oil , replaced coolant, cleaned front camshaft plug and temporary sealed it . Greased prop and a genral inspection underneath . All done by 1pm including drive back home from workshop .





While looking underneath found rear diff weaping so need a new seal for that and once spring here some chassis cleaning and treatment in areas the back end has been done and is solid . Tapping with hammer etc .



Also found engine has been protecting the front part of chassis ... leaks galore . But as already said I cleaned front up and re sealed for now . Ordered a injector loom and a cam cover gasket and camshaft plugs and as only cheap a fpr gasket but realised after filter and o ring . But not 100% sure coming from there . So will do those few bits and give a dose in jizer etc and power wash off .



I have some maxxis bighorns on there way to me , so will fit them one evening after work . I think initially going to be curing problems before many modifications .

All the best , Matt

Nice to see a D2 getting some treatment!

callisr said:

Nice to see a D2 getting some treatment!

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Cheers! My theory is no matter how old a vehicle they all need looking after . When I went to view this one I knew would be a bit of a on going project . The chap that had this started doing a few bits but I think he may of sold being too much for him.

Being able to do work in a workshop environment helps alot . Main things to try to get under control are the oil leaks to start with . And go from there .

See so many discoverys being broken for spares when expect just need some time spent on them .

Good start by giving it some attention. I’m sure it’ll repay you with plenty of reliable use and laning. Keep the pics coming!

Knappster said:

Good start by giving it some attention. I’m sure it’ll repay you with plenty of reliable use and laning. Keep the pics coming!

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Cheers buddy , is it just me or do far too many people break discos instead of repairing them ?

Mud terrain thres have turned up today . Only went for these as get very good reviews on road considering there a mud tyre .

764s great choice of tyre.

Going to be a smashing motor when you gets it sorted.

dieseldog69 said:

764s great choice of tyre.

Going to be a smashing motor when you gets it sorted.

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I went for these as not silly priced like Goodrich but get good reviews for on road believe it or not .

Only thing I want to do something is a CDL but I have no difflock in the box . Probably see how I get on

Matt2e0fgx said:

I went for these as not silly priced like Goodrich but get good reviews for on road believe it or not .

Only thing I want to do something is a CDL but I have no difflock in the box . Probably see how I get on

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764s are brilliant on road, I have them on my classic and I push it pretty hard on and offroad, they hold up well and handle very nicely for a MT!

Trailstar said:

764s are brilliant on road, I have them on my classic and I push it pretty hard on and offroad, they hold up well and handle very nicely for a MT!

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Glad to hear made a good choice !

Well today I had a vehicle locksmith to rebuild my keys and cut new blades due to no buttons on the fobs . All working , except I have a weak drivers door actuator . It will lock with central locking but when unlock you have to unlock all doors the use the key to open the drivers lock .

Is this a common fault ?

Matt2e0fgx said:

Well today I had a vehicle locksmith to rebuild my keys and cut new blades due to no buttons on the fobs . All working , except I have a weak drivers door actuator . It will lock with central locking but when unlock you have to unlock all doors the use the key to open the drivers lock .

Is this a common fault ?

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No not really, it does happen with age though.

For your CDL, have you considered an Ashcroft ATB unit to give you a kind of automatic CDL? If you really do want a manual CDL then you could swap your transfer box for an earlier 300Tdi transfer box.

dieseldog69 said:

No not really, it does happen with age though.

For your CDL, have you considered an Ashcroft ATB unit to give you a kind of automatic CDL? If you really do want a manual CDL then you could swap your transfer box for an earlier 300Tdi transfer box.

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I'm going to replace the drivers door actuator at some point . Opens all other doors without the key so is fine at moment .

I did think to do a transfer box swap is a option . I will have to have a look into the Ashcroft unit . But from what I hear they are still very capable with traction control . A little aggressive on the countryside and your vehicle though .

Well there on, what a swine to balance compared to road tyres !

Bit more of some of that type of maintenance that you do to give to peace of mind today .

Decided to replace the injection loom along with a new gasket and inspect to see if my seal on the front camshaft plug is holding .

Well good news , not a dribble from after a weeks driving.



Whilst had the top cover off I inspected rear plug and that is bone dry . I was tempted to replace the rear cover but thought what does it actually do !



New loom fitted . While under there I looked closer at the idea on fitting ferite clip on beads to reduce rf interference for my radio equipment ( amateur and cb ) but no chance on the short length of wires .

All sealed up and driven fine since . All I could do today whilst dodging the rain !

On Christmas eve afternoon I decided as have a bit of time to fit the thermostat housing and actually get a working heater .


Still after a 20 minuite drive to work today the temperature guage is not too far up the guage .



I put this down to a cold running engine with a big block taking a long time to heat up this time of year but it was alot warmer in the cab .

Next job once the new year is hear will the to rebuild the FPR while keeping an eye on the steering pump , when it's cold it groans reversing off the drive. But after that it is fine. Yes it's fairly wet and evidence been leaking a while . I topped the fluid up when bought it but not dropped a huge amount . May just order a genuine low pressure o ring and add some of the power steering system sealer .

Hope we all had a festive Christmas?

I find CDL to be useless when compared to the D2's 4 wheel TC.

Nice car/thread,

Started to tint my rear windows today in 5% limo black . It's not perfect but it's the effect I want and may at a later date get done professionally but for now it will do .

All to do is rear and the alpine windows

Did the dreaded FPR what a pain in the **** job , arm covered in cuts blood all over the inlet manifold . But once rebuilt it I figured got to be a easier way, I had a suggestion on here to try go from underneath. I cant remember who suggested it but was far far easier , 2 bolts and a nut and 2 cables and starter is off and much easier . Cleaned starter at same time with brake cleaner .




Also fitted new o rings to the fuel lines . Primed and fired up and no leaks .

Today (sunday) fished the window tinting , removed rear bonded in window tints and replaced and cut my own and came to the idea the pre cut film quality is naff ! Off the roll much thicker and goes on much better ! Rear door and alpine windows all done .





Had time to do rear door and body rear windows on brothers 110 van also.

I also decided I'm going to sort of convert into a overland / camping vehicle . More exploring wales , lakes, yorkshire etc . 28 days holiday a year and only used just over a week this summer so I can see lots of long weekend trips away . Plus single man I rarely carry passengers , maybe one at most .

Anyway my idea is 2 large boxes , one in boot which can stay in with centre row seats in and rear seats removed . But remove seats and add a second box and a fold out frame with front seats forward a few notches I can get just over 6ft in length and advantage of plenty of storage underneath.

So I've made a start on boot box .



Ran out of 4x30 screws for battern framing . More pictures in next few days when try for fit .