Just finished the work and she's all put back together. Here's all that was done. I'm probably missing a few things on this list as there was a lot:
- Pulled engine, auto transmission and transfer box
- Cleaned everything (engine, transmission, under truck and in engine bay)
- Replaced crank
- Installed R380 manual transmission
- Replaced transfer box with the one that came with the transmission (almost identical in gearing to the one I had in the truck)
- Had flywheel resurfaced
- New clutch kit
- New crank pulley and damper
- New fan pulley
- New timing belt
- New water pump
- Timed engine
- Timed valves
- All new gaskets along the way
- New clutch release guide
- Replaced pedal box (LHD pedal box for 5-speed D1 - luckily found one)
- Replaced brake servo and vacuum line to vacuum pump
- Replaced clutch master cylinder
- New clutch slave and custom made soft line
- Replaced center console with one that had cutout for 5-speed lever
- Installed Syncroworks slickshift
- New fuel filter and oil filter
- Removed transmission cooler and lines
- Greased propshafts
- New fluids of course (oil, coolant, MTL, 90w)
There were a few things to learn along the way:
- Couldn't get the engine the starter going and found that we needed to pull the park/neutral position switch from the auto transmission and modify the switch plug to always close the circuit; allowing the car to start. Thought for a moment it would be cool to run it to a switch in the cabin to use as a safety feature that would only allow the car to start if the switch was on.
- Need to find some sort of foam or other dampening for the 5-speed shifter hole in the center console. I have the boot for the lever but not the gaiter that goes under it or any other foam. So it's considerably noisier at the moment.
- Seem to have not taken enough care in replacing the rear main seal or I should have replaced the t-seals...as there is a leak through the wading plug hole at the base of the bell housing. (
https://discoweb.org/showthread.php?p=1076661) I'll have to go back in to figure that out.
- Had to pull off and retighten the plate on the back of the transfer case as it was leaking after install (seems to be good now)
- Speedometer wasn't working initially and just hadn't plugged into the speed sensor in the transfer box
- Fuel lines were a bit loose (to and from the pump) and upon first startup engine would turn over but wouldn't start. Tightened those fuel lines and then loosened the fuel line into the engine at cylinder 1 until fuel was clearly coming out and then re-tightened.
- Getting the pin in and clip on for clutch master cylinder to clutch pedal is a pain unless you loosen the master cylinder from the pedal box. I learned this the hard way.