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.
That took longer than I would have liked, but on round 3, I finally got made a trasfercase frame mount adapter that worked. Now the engine is in. I can conclusively say the alternator will not fit, like it's close... but not nearly close enough to make it work. So I'll pull the A/C compressor and throw the alternator over there with another custom fabricated bracket, then get new belts.
The rest of the engine clearance looks like it was made for the rover, PLENTY of axle clearance and no other interference issues.
Next steps are to get my engine mounts fabricated and welded in.
what is the white plastic thing with a coil spring on the side of clutch pedal?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.
what about relocating swapping locations of this belt pulley to the bottom alternator location and alternator to the upper area if possible it would benefit the alternator for high water crossing situationsThat took longer than I would have liked, but on round 3, I finally got made a trasfercase frame mount adapter that worked. Now the engine is in. I can conclusively say the alternator will not fit, like it's close... but not nearly close enough to make it work. So I'll pull the A/C compressor and throw the alternator over there with another custom fabricated bracket, then get new belts.
The rest of the engine clearance looks like it was made for the rover, PLENTY of axle clearance and no other interference issues.
Next steps are to get my engine mounts fabricated and welded in.
That was my primary path. But the radiator clearance won't allow it.what about relocating swapping locations of this belt pulley to the bottom alternator location and alternator to the upper area if possible it would benefit the alternator for high water crossing situations
There's a balance here... Making this the most perfect ideal 4 wheeler in the world... vs getting it driveable sooner than later.
No offense, but I interpreted this as something similar to what David Freiburger said about the vehicles on ROADKILL. "Don't get it right, just get it running." BTW, I have a couple of t-shirts and a hoodie with this on the back of them. Lol
Curious. This pneumatic setup - is that a “thing“ or is it something you’ve thought up as a solution and are pioneering it?Well quite a few steps back - but I'm excited about the new direction. The transmission shift cables will NOT fit with the transfer case shifter directly infront. At least not without being super janky and not something I'd be interested in trusting on the trail or in the wild.
So I'm going to pull the transmission and transfer case down, and remove the transfer case shifter and convert it to pneumatic. I will have 2 single-acting air cylinders put in place on the transfer case. One for selecting low range/ high range, and one for selecting 2wd vs 4wd. The LT230 tcase is unique in that those selectors are independent. I think this will clean up the vehicle operation and make everything move much smoother. It's a bummer since I put a LOT of time and effort into making the shift linkage work with the adapter, but oh well such is the way when doing something so custom.
So that means that once I pull the transmission and transfer case I will have to remove the shift linkage, then design and fabricate mounts for these air cylinders. Then the transmission shifter will have a clear shot in, and work very nicely.
In the good news area, I have the new A/C condenser installed, as well as the new radiator and fan. I just need to drill a couple quick holes to get the intercooler mounted and the cooling package will be complete.
Nah not a thing. But it was my contingency from a long time ago if I was unable to get the tcase shifter to work woth the adapter. I solved that problem, but ran into another. Oh well. It shouldn't be terribly difficult to do. Simply removing the transfer case and transmission is going to be the biggest pain in the ass part of this (and then reinstalling)
