109 Expedition rig build

[Mercedesrover]

Hi All,

After posting in the General Discussion section I decided to start a thread over here about the build I’m doing. I recognize a few names over here so some of you might be familiar with it. I’ve had an 88” Series III for a number of years that has been modified and prepared for long-distance trips, of which it’s been on a few. I’m very happy with this truck and it performs very well in all but two categories, the first being top-end speed. It’ll maintain 60 all day and do 65 in a pinch but it’s happier at 55. I’m building this new truck with the hopes of being able to maintain 70, even on grades and be comfortable on the highway. The second shortfall is the amount of available space. With my wife and two dogs along for the ride, packing is an adventure in frugality. With the extra 21” of wheelbase in the 109, it should have plenty of room. Besides that it will mirror the 88” in many respects. Changes have been made with simplicity and reliability as the first priorities followed by ease of repair, maintenance and availability. The 300tdi is a great motor but need a part in North Dakota and you’re out of luck.

I’m starting out with a ’67 NADA 2.6 truck that I acquired last year. Not much left of the truck, as you can see, but it has the desirable 2.6 bulkhead that affords me the extra room to use the engine I want.

The truck will get the following parts thrown at it.

New Stage-One galvanized frame, modified and re-galvanized
Mercedes 3.0L 5-cyl turbo diesel
Rebuilt NP435 4-speed with a Pangolin output shaft and adapter plate
Ashcroft high-ratio transfer case
Toyota 4:10 E-locker center differentials in Land Rover housings
Seriestrek 30-spline axles
FJ60 power steering

The bulkhead is done
The frame is modified and ready for galvanize
The motor is here and oil pan has been modified, motor mounts made.
The bellhousing is built and ready
Tranny and rebuilt kit are here
Waiting on Pangolin adapter kit
Transfer case is here
Differentials are here.
Axles are on their way

I hope to have a rolling chassis by spring when work on getting the body together will begin. Most of the original panels are shot, as you can imagine. I’ve found a decent tub but most everything else will be replaced with new.

It should make for a pretty reliable and capable rig with good range, and one that can spend a few days on the highway getting to different locations before heading into the bush.

I’ve posted a few pictures below and will keep adding to this thread as progress continues. If you have any questions, comments or suggestions, feel free to add to it.

Jim

[overlander]

Sweet Jesus. You are going to have a fabulously interesting ride when all is said and done, but you'll be the Osama Bin Laden to purists around the world. It's like a romanesque marque orgy for expedition grade automakers.

so what marque are you going to put on it when you're done?

BTW, have you considered changing your userid to rovermercedes? just a thought...

[ChuckB]

Very cool!! I have been on your webpage numerous times. Looks like a great combination of reliable parts. I also love the old Rover looks. Too bad you couldn't use the H55F... you would have made a lot of Cruiser friends!!!! I'm hoping to convert my FJ55 to diesel. Just not sure which motor yet?

[Mercedesrover]

I thought about the H55F and almost did it for no other reason than the 5-speed. It's kind of an odd tranny here in the states though, and it's a little long. I'd also have to run the LC T-case which I didn't want to do. What I'm loosing in gears with the NP435 I'm gaining in cost, availability, reliability and the fact that I can keep the Series T-case.

If you're serious about mounting an H55F to the back of a 617/616 Benz, let me know. I've got a couple of brand new Benz bellhousings that I ordered from Germany and I'm thinking about ordering what's left over there. (There are only 4 more in the world.) If you give me the stick-out length, input bearing retainer diameter and the basic shape of the bolt pattern I can probably make you one.

Here's the finished bellhousing for the NP435

[bovw]

This is going to be a very good read. I'll be waiting for updates with the anticipation of the next Overland Journal!

[TeriAnn]

Hey Jim,

Have you considered a 2 door rear tub on the 109? With bad panels it looks like a good time to think about what goes on behind the front doors. You can get more wall space for cabinetry & such out of a 2 door and those taller side benches allow more stuff to be mounted underneath at frame level. With two people you will need all the rear space you can get.

I looked at the 5 cylinder once and was dismayed by all the hangy down parts on the right side of the engine. Are any being moved? How do you plan to thread the front prop shaft through the obstacles?

You didn't mention it but I assume you are planning on a front disc brake conversion. Holding a 109 stationary in a steep nose up attitude immediately becomes an extreme isometric exercise. Those dual leading front shoes help in forward braking but provide very little help in the reverse direction. Its on my list as an important safety upgrade.

I'm glad you are documenting the engine swap. There has been a lot of interest in it but people usually just look at all the hangy down stuff sitting around frame level and walk away.

Good luck with it

[ChuckB]

I thought about the H55F and almost did it for no other reason than the 5-speed. It's kind of an odd tranny here in the states though, and it's a little long. I'd also have to run the LC T-case which I didn't want to do. What I'm loosing in gears with the NP435 I'm gaining in cost, availability, reliability and the fact that I can keep the Series T-case.

If you're serious about mounting an H55F to the back of a 617/616 Benz, let me know. I've got a couple of brand new Benz bellhousings that I ordered from Germany and I'm thinking about ordering what's left over there. (There are only 4 more in the world.) If you give me the stick-out length, input bearing retainer diameter and the basic shape of the bolt pattern I can probably make you one.

Here's the finished bellhousing for the NP435

Thanks for the offer!!!! I wish I was a little bit closer to the reality stage of my buildup... but unfortunately I need more time and $$$$. I'll keep this in mind though for the future.

[dieselcruiserhead]

Hi Jim congrats and great...
I wish I had better photos but I have a H55F in the 109 in the truck for sale in my sig. The only real odd thing was they had to fab a custom dog house which was a little unrover like and was done decently but not excellently.

My daily driver was the OM617 through about last winter when at 340K miles it finally stopped starting well in the cold (-6F here in the mornings sometimes), but was a great engine. I think it will go well into a 109. It can cruise as you know as high as 3500 rpms easily and enjoys the higher revs. That said I probably would have considered the overdrive option a little more heavily but you will be fine. And the NP435 is a hell of a reliable old school transmission.

There are excellent writeups on retrofitting the e lockers to different vehicles. I did it with my last 55 and did not use resistors in the path it fried my locker in about 6 months of regular use and nearly caused a fire at out on Kane Creek during Cruise moab, camping one night, two years ago. The single pull double-throw momentary switch method also works great and I've heard of no failures that way even without resistors. I am doing e-lockers with my current build and plan to use the OEM switch and computer. That said, you can wire from scratch easily and use resistors and relays, or even convert to cables (the best/easiest option) using a kit from Downey.

Good luck and looks great. Also be careful not to breath those fumes when welding.. I have heard they are a ***** with the illness and that the sickness actually can lead to permanent damage contrary to most reports. I plan on galvanizing my chassis and only hope I get most of the fab done before then.

Cheers,
Andre

[Linus Tremaine]

Jim,
do you think, at this point in your project, that the 5 cylinder MB engine could be made to fit in a NADA truck without any mods to the bulkhead?

Perhaps by moving the engine and trans forward? I have a NADA dormobile and its pretty original. I would hate to cut it up.

[rfun]

absolutely great job...