D90 Rebuild......

[99Disco2]

Thanks... am running a RaRo ZF4-HP22 so it's all manual shift. If you want to keep the HP24 the guys back in the UK use Compushift... http://www.hgmelectronics.com/products- ... mpushiftii

Search on the D44 board, think there were some threads on there about using & setting it up.[/quote]

Thanks for the Compushift link,I will do some research on it.
As for yours, I take that it is a Range Rover ZF4 right?
What year is it from and how did you get it to run manual shift?
My wife wants to keep the auto box but doesn't mind shifting it her self, I would rather have a R3380 or LT77 instead.

Chris

[LandyAndy]

As for yours, I take that it is a Range Rover ZF4 right?
What year is it from and how did you get it to run manual shift?

Yep, came out a RaRo years ago... haven't a clue what yr though... and manual shift as in... it don't need a computer to make it work like the HP24 :wink:

[99Disco2]

As for yours, I take that it is a Range Rover ZF4 right?
What year is it from and how did you get it to run manual shift?

Yep, came out a RaRo years ago... haven't a clue what yr though... and manual shift as in... it don't need a computer to make it work like the HP24 :wink:

Ah got it now, sorry I had a brain lapse there
My current tranny (HP24) is fully electonic and yours the HP22 is full maual like an old school Chevy Turbo 350, correct?
Now wasn't the HP22 used in the D1's as well?
Oh and the HP24's tourque converter won't fit in the HP22 right?
I was reading on "Paddock Spares" web site and they state the bell housings are different and not interchangable, what engine block are you running?

Sorry for bonbarding you with questions

Thanks also for your help

[mojigglins]

Wow!! Amazing! Build!

I was just wondering what t-case are you running and gear ratio, LT230 1.667?

Thanks for sharing!!

[LandyAndy]

Wow!! Amazing! Build!

I was just wondering what t-case are you running and gear ratio, LT230 1.667?

Thanks for sharing!!

Yup, with std diffs... Same as D44 run in their trucks. About the ideal ratio for 35's ;)

[LandyAndy]

Not a lot of progress these past weeks, but did pick up a new alum rad whilst I was back in the UK... saved a bunch on tax & shipping :D

http://i946.photobucket.com/albums/ad30 ... 86eb55.jpg

http://i946.photobucket.com/albums/ad30 ... 82437d.jpg

As funds are a bit thin on the ground at present made a start on the custom dash, decided to use the Vintage Air A/C unit as I already had it (was going to use the OEM heater & mod it) & they get good reviews. So, made up a small cradle from 3/4" 100 wall tube & some strip stock to mount the A/C unit just off centre on the bulkhead.

http://i946.photobucket.com/albums/ad30 ... 1fc0db.jpg

http://i946.photobucket.com/albums/ad30 ... 5fd8ab.jpg

Will be keeping the dash top crash pad & the RHD instrument binnacle as it'll mount easily onto the dash front and why reinvent the wheel. Next to source some round facia vents & defrost ducts so I can lay the dash out, have already got the Carling switches and a 6 way mounting bracket for them also. Was thinking that the switches should go above the A/C unit as that space will become quite full once all the ducting is attached. Not sure about where there will be space for a radio... mine is actually mounted into the Laselle headlining but if anyone else wanted one it'd need to find a home in the dash..... ummm.... need to get the thinking cap on for that one :wink:

[LandyAndy]

Been a while since last update...... have spent many hours on the CAD getting the bulkhead & top crash pad models correct and the dash drawn up. Decided not to use any LHD dash parts in the build at all and just use what I had, any other LR parts needed are easily available on Ebay or the usual LR suppliers. Here is the model to date.

http://i946.photobucket.com/albums/ad30 ... 92947f.jpg

After getting just the ends cut, adjusted & fitted the bulkhead model needed a few tweeks, then I finalized the main dash panel and made a cardboard mock up. A few more adjustments to the locations of switches etc and then off it went for cutting.

http://i946.photobucket.com/albums/ad30 ... db61c5.jpg

Now here is the drivers side tacked up and in place. Will make some final adjustments to the model but nothing that means a recut of this part. :D

http://i946.photobucket.com/albums/ad30 ... 9de362.jpg

http://i946.photobucket.com/albums/ad30 ... 02047b.jpg

http://i946.photobucket.com/albums/ad30 ... aaa78a.jpg

The old heater control levers have been repurposed to open & close the bulkhead vent flaps using heater control cables and some custom brackets. I've added a side window vent for defrosting & 12v/USB charging points for phones etc. Now just waiting on hinges/catch for the passenger side glove box from Southco dealer and a D1 interior grab handle too. I can then get the passenger side finished off as the main panel is the same profile as the drivers side. After that I can focus on the centre section that covers the HVAC unit & the top pod that'll wrap up & over the top pad where the old ashtray was.

[LandyAndy]

Haven't updated this in a while, so here are a few more pics :

LED lights for the rear cargo area.
http://i946.photobucket.com/albums/ad30 ... 219e1b.jpg

LED lights to see where I'm going :D
http://i946.photobucket.com/albums/ad30 ... 5f0bb5.jpg

Limb riser tabs & couple more brackets for LED ditch lights.
http://i946.photobucket.com/albums/ad30 ... 0de12e.jpg

Got a bought a pair of new seats in the sales.
http://i946.photobucket.com/albums/ad30 ... 075398.jpg

Will use the Qt f/g seat mount.
http://i946.photobucket.com/albums/ad30 ... 21ae66.jpg

With some adaptor brackets to make them easy removable.
http://i946.photobucket.com/albums/ad30 ... e9a61e.jpg

[LandyAndy]

Decided to make long term servicing easier up here in the sticks..... so, out came the old RaRo motor !
http://i946.photobucket.com/albums/ad30 ... 6a41e1.jpg

And in it's place will be.... :D
http://i946.photobucket.com/albums/ad30 ... f28a78.jpg

And behind that there is a NV4500 linked to the LT230 with one of Nicks adaptors.
http://i946.photobucket.com/albums/ad30 ... 5a3a5a.jpg

I'll also be fitting a Behemoth Drivetrain Strong Box between the NV & adaptor next, that'll give me a crawl ratio of 180:1..... :bounce:
http://www.behemothdrivetrain.com/STRON ... _KITS.html

So, I have a used NP241C to donate it's guts... not bad for a pack of beer :wink:

[LandyAndy]

Finally, progressed the custom dash to a point where it needs final welding & then powder coating.

http://i946.photobucket.com/albums/ad30 ... b6fcba.jpg

http://i946.photobucket.com/albums/ad30 ... 1ae7b4.jpg

http://i946.photobucket.com/albums/ad30 ... 3b0813.jpg

http://i946.photobucket.com/albums/ad30 ... 62e346.jpg

http://i946.photobucket.com/albums/ad30 ... b04ad1.jpg

And that's about it so far....

[franko]

So....you applying for Alaska off road warriors season 2 ;-)

[LandyAndy]

So....you applying for Alaska off road warriors season 2 ;-)

I doubt it'll be finished for then... lol

[99Disco2]

[quote="LandyAndy"]Decided to make long term servicing easier up here in the sticks..... so, out came the old RaRo motor !
http://i946.photobucket.com/albums/ad30 ... 6a41e1.jpg

And in it's place will be.... :D
http://i946.photobucket.com/albums/ad30 ... f28a78.jpg

And behind that there is a NV4500 linked to the LT230 with one of Nicks adaptors.
http://i946.photobucket.com/albums/ad30 ... 5a3a5a.jpg

I'll also be fitting a Behemoth Drivetrain Strong Box between the NV & adaptor next, that'll give me a crawl ratio of 180:1..... :bounce:
http://www.behemothdrivetrain.com/STRON ... _KITS.html

So the adapter you are using, was it bought locally?
I am looking at an adapter for the Dodge 23 spline NV4500/NV3550 for a diesel conversion.

[LandyAndy]

I got the adaptor kit from Nick over on Defendersource, as far as I know he only makes the GM 32 spline spud shafts.... Check on EBay, I think there is a Dodge adaptor sometimes listed but I don't think it has the holes in it for the mounts.

[99Disco2]

I got the adaptor kit from Nick over on Defendersource, as far as I know he only makes the GM 32 spline spud shafts.... Check on EBay, I think there is a Dodge adaptor sometimes listed but I don't think it has the holes in it for the mounts.

You are right about the Dodge adapter, it's from Diesel Conversion Specialist for $599.
Does Nick on Defendersource still sell the GM one's.

[LandyAndy]

A few updated pics.....

Drive line assembled with the crawler box.
http://i946.photobucket.com/albums/ad30 ... fac8nw.jpg

Trial fit of the Goat Build PAS pump & Alt relocation brackets.
http://i946.photobucket.com/albums/ad30 ... bapmsp.jpg

Hi/Lo lever flipped round for easier cable shift hook up with the crawler box.
http://i946.photobucket.com/albums/ad30 ... zuckr0.jpg

Added the TD5 clutch pedal.
http://i946.photobucket.com/albums/ad30 ... 6xibrx.jpg

Trial fit of the Vortec to check water pump clearance to the Allisport rad.
http://i946.photobucket.com/albums/ad30 ... ppless.jpg

Might need to swap the oil pan out for a Camaro one if clearance at full bump is an issue.
http://i946.photobucket.com/albums/ad30 ... amlbk5.jpg

[LandyAndy]

I got the adaptor kit from Nick over on Defendersource, as far as I know he only makes the GM 32 spline spud shafts.... Check on EBay, I think there is a Dodge adaptor sometimes listed but I don't think it has the holes in it for the mounts.

You are right about the Dodge adapter, it's from Diesel Conversion Specialist for $599.
Does Nick on Defendersource still sell the GM one's.

Yep... drop him a PM to reserve, he has another batch in manufacturing progress I believe.

[HeadDamage]

I forget, have you lengthened the wheel base?

[LandyAndy]

I forget, have you lengthened the wheel base?

Yes, to 100". Looks like if I fit a short drive shaft & carrier bearing off the 3 link x-member, I'll be able to have the same length drive shaft to the axles front & rear.

[LandyAndy]

Major milestone reached.....

http://i946.photobucket.com/albums/ad30 ... rjvted.jpg

http://i946.photobucket.com/albums/ad30 ... zmtapl.jpg

http://i946.photobucket.com/albums/ad30 ... otei1r.jpg

Good clearance to the front x-member too, so that won't need to be reworked.

http://i946.photobucket.com/albums/ad30 ... vkymhg.jpg

Well pleased :grin

[TOLON]

Nice! Will have to stop in for a looksee...I'll bring beer!

[LandyAndy]

A few small jobs completed, PAS pipes to the steering box.

http://i946.photobucket.com/albums/ad30 ... qmijwg.jpg

Moving the engine & drive line back an additional inch has given enough room for medium frame Spal electric fans on the Alisport rad :D

http://i946.photobucket.com/albums/ad30 ... u4i6cm.jpg

Version 1 of the GM ECU mount.... version 2 has the fuse box mounted to the rear for a lower profile.

http://i946.photobucket.com/albums/ad30 ... vre1h7.jpg

Engine loom pruned out & modified for stand alone use, just the gauge wires to add then loom up.

http://i946.photobucket.com/albums/ad30 ... tfcviq.jpg

[LandyAndy]

Not been round here for a while, got a new job... working on the house... you know the score...

Anyway a few updated pic's... fuel system all plumbed up

http://i946.photobucket.com/albums/ad30 ... izsd6m.jpg

Custom schedule 40 exhaust manifolds being made

http://i946.photobucket.com/albums/ad30 ... hcnayp.jpg

Engine harness all finished

http://i946.photobucket.com/albums/ad30 ... anbljk.jpg

Front propshaft centre bearing from Rakeway in the UK to get it over the 3 link cross member

http://i946.photobucket.com/albums/ad30 ... s7hfyb.jpg

Heater fully plumbed & installed

http://i946.photobucket.com/albums/ad30 ... iu6l8e.jpg

Started a new custom wiring loom to replace the old cracked one and all new switches etc

http://i946.photobucket.com/albums/ad30 ... h49oz8.jpg

http://i946.photobucket.com/albums/ad30 ... lbreao.jpg

And the seatbox is all back in with custom removable mounts for the seats to aid in servicing & cleaning

http://i946.photobucket.com/albums/ad30 ... 6l3kmw.jpg

And finally the exo cage is all powder coated & fitted

http://i946.photobucket.com/albums/ad30 ... 7mn5cz.jpg

http://i946.photobucket.com/albums/ad30 ... tjitj2.jpg

That's about it really, been a very busy 7 months since starting my new job... hope to make a bit more progress over the next few before the snow flies !

[D Andersen]

What fusebox did you use? I have to replace mine on my MOD 90

[ANDYD]

Looking really good Andy, very nice work. Thanks for the update.

Bet you cant wait to get all those nooks and crannies full of gooey, mucky mud!