2.3Eco in a Disco

[got3fords]

What do you do in your spare time?

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[Av8or1]

Got 35s on. Probably dumb since it'll still be 6 months to a year until it's driving, but I put this under the "motivation" category.

 

[Colo_Ranger]

 

[Av8or1]

Now I'm having some impure thoughts about doing this trans swap in my Ranger too...

 

[Colo_Ranger]

Now I'm having some impure thoughts about doing this trans swap in my Ranger too...

you’d make a lot of people happy. Especially if it ended up being relatively easy

 

[Av8or1]

you’d make a lot of people happy. Especially if it ended up being relatively easy

From my research, I know itll bolt up directly to the engine, and transfer case. It's also cable shift so exact positioning isn't that difficult. My understanding is a lot of the mounting for the shifter and clutch are existing from the global ranger, hell in fordscan it even has an option to change it from "automatic" to "manual". It really might not be that difficult. Once the Rover is done and reliable, I think i'll DD that to put some miles on it, while also swapping the Ranger Trans.

I think the biggest challenge will just come from making it happy with the vehicle computer since I'm sure the wiring harness is different.

 

[cfhgarza]

Dude! This is awesome. Can’t wait to see how it turn out

 

[Dereku]

You make a ranger manual how to, people would pay just for the knowledge

 

[GhostStrykre]

yeah concur. people would pay. myself included. hell, i'd do the manual transmission swap and call it "preventative maintenance" lol.

 

[Av8or1]

Alright for anyone looking for info on this transmission into Rangers, you can find it here:
https://www.ranger5g.com/forum/threads/manual-trans-swap-mt88.32696/

Now back to the Disco. I finally have the electronic throttle pedal and Bronco clutch pedal in. It was no easy task requiring significant fabrication including cutting the clutch pedal in half and re-welding it back together. Ford was not messing around, the pedal is 1/2" thick 4140 steel so that was quite a bit of work to cut through. All of the clutch connections, including the reservoir are all made and completed - it's ready to plug straight into the transmission. Unfortunately due to a miscalculation in my welding, the pedal is a bit crooked, but oh well it's in, connected and solid. Considering how long this portion took, it is what it is. I may revisit it in the future, but for now it's not worth the time considering its functional.

Now the good news is that the next task is putting on engine accessories, doing a dry fit of the drivetrain, and then getting the engine in! Progress should speed up a bit now that this bit of tedium is complete.

 

[Av8or1]

Well I was hoping this winter would be time for significant progress, but it continues to be slower than I'd like. Since my last post this is what's been completed:

• Old engine mounts cut off, frame rail sanded and painted with weld-through primer
• I straightened the clutch pedal, I'm too anal to deal with it being crooked
• The fluids were changed in the transmission and transfer case
• The transfer case needed some modification, there is a solenoid when stock to prevent you from shifting, which is not necessary. I removed it and added a blanking plate.
• The engine is fully dressed to include:
  • 370 Amp alternator! For running lights, air, winch, etc.
  • A/C compressor from a mustang that was totaled with 3k miles on it
  • Serpentine belts
  • Flywheel
  • New clutch
  • Coolant outflow pipe
  • belt tensioner
  • throttle
  • engine mounts
• Transmission is mounted up

But then I ran into a snag while working on full drivetrain dry-fit. The adapter, at least in the land rover Discovery 1 has the transfer case clocked at the wrong angle. This will make it hang lower, and the frame mounts won't work, and neither will the shift lever. Luckily I do have a mini-CNC Taig Mill, so I will re-drill the bolt pattern at the correct angle, but it continues to be a set-back.

Once this is corrected - I will complete dryfit. Then I'll split the adapter and mount the transfer case in the Rover. Drop the engine in, measure for new engine mounts, send that to Send Cut Send, weld that up, weld it in and then the engine is in. I'm close... but always two steps forward and one step back.

 

[Colo_Ranger]

I love builds like this. Awesome work.

What alternator did you use that has 370a?

 

[Av8or1]

I love builds like this. Awesome work.

What alternator did you use that has 370a?

I took the brand new 180A one that came with the crate engine to a local alternator shop https://www.finickiautoelectric.com/. I told them all I was looking for was maybe 230, or 250A at the most. They said their supplier has a 370A kit! I said reliability was the most important thing to me more than output, but they swore they have used this kit in the past and it lasts the life of their vehicles. Hopefully it works well, if not alternators are easy to swap, but not so easy on the trail. I'm using an electric power steering pump out of a Dodge Durango and that pump will suck some amps down.

 

[Colo_Ranger]

I took the brand new 180A one that came with the crate engine to a local alternator shop https://www.finickiautoelectric.com/. I told them all I was looking for was maybe 230, or 250A at the most. They said their supplier has a 370A kit! I said reliability was the most important thing to me more than output, but they swore they have used this kit in the past and it lasts the life of their vehicles. Hopefully it works well, if not alternators are easy to swap, but not so easy on the trail. I'm using an electric power steering pump out of a Dodge Durango and that pump will suck some amps down.

Awesome! Thank you!

 

[Av8or1]

Machining the adapter is done - one step closer. Transfer case is mounted. Though now I need to machine a standoff bracket for the shift linkage.

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