The DiscoDavis Discovery 1 Mayhem Thread

Nonimouse

Cynical old bastard
I'd suggest a Syncro transmission from Shabs Percy. Ashcroft are good - but have lost the way slightly now they are so big. Shabs hasn't...
 

DiscoDavis

Explorer
Long time since I updated this.

Elizabeth made it all the way to August doing about 60 miles a day driving to and from work, about 6000 miles since we got her with the screaming 5-speed. Kept changing the fluid every few weeks, every time it looked dark and had metal sand particles in it. Then late one summer evening the transmission started a terrifying rattle right after leaving the freeway near home. Nursed her back into the driveway and she's been parked there since. I kept my promise and there is now an Ashcroft gearbox sitting in the barn waiting for her. Not sure yet when it will go in, but I haven't given up on our Arizona adventure car just yet.

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Cannot say I have ever seen a drivetrain component look this clean. Especially not on Elizabeth...

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DiscoDavis

Explorer
Last week dropped her off with the expert car surgeon Colin @ CT

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Several mad dashes around the area scrounging parts up later,
>clutch plate
>slave cylinder
>clutch fork (got two since not sure what fits)
>fan clutch (elizabeths is seized solid) (for later)
>some U joints I had sitting from the 110 (Colin called and said all of mine were bad on Elizabeth... whoops)

Then came in a text message from expert car surgeon:

"You need a transfer case"
"The center pinion shaft nut lost its stake and backed off"
"The main gear ran into the case"

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That explains part of the horrendous racket the last few days she drove.

They found a case and that's going on the car as well. To be continued
 

Ray_G

Explorer
Hopefully it's an LT230Q; a nice upgrade if you had an earlier suffix


Sent from my iPhone using Tapatalk
 

DiscoDavis

Explorer
Hopefully it's an LT230Q; a nice upgrade if you had an earlier suffix

Sadly in this case the mandate was: closest and cheapest case we could find in the best shape. Would have been really nice to find a Q though. Honestly it will be a night and day improvement over the howling siren song of the dying drivetrain she had before. ;)
 

DiscoDavis

Explorer
Update 12.22.2017

Right before Christmas, was hoping she would be done, BUT it has been a rats nest of unknown issues that continue to crop up.

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>Ashcroft R380 in
>"New" (donor) t-case in
>reverse light switch in
>diff lock light switch in
>2x new U joints on propshafts
>new clutch plate in
>new clutch fork in
>new throwout bearing in
>new brake master cylinder in (completely leaked out the old one over 1 month)
>new rear axle brake lines (had been without working rear axle brakes since ???)

Remaining issue is a very weird softness in brake pedal, possible piston/caliper issue somewhere... TBD

The shop/Colin has done 100% of the heavy lifting on this car, I don't think I'd be able to cover all these items stacked up. The LT230 we got was an odd one, was a later case (1997-98?) but it had a non crossdrilled input gear set, so Colin got one ordered from Ashcroft and we waited until that came, then he swapped the two sets for a good and durable trans/Tcase combo.

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To be done when it comes back home:

>new fan clutch (no more jet engine sound)
>rear lamp guards I found
>new door spare that matches current 5.5's
>front fascia rebuild
>rewire some electrics
>rear CT lamp like her sister.

Hope you all had a nice holiday
 
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DiscoDavis

Explorer
Got the car back last night, drove it to work today. Laundry list of things replaced:

>Ashcroft R380 installed
>new clutch plate
>new fork (cast LR model for anyone interested)
>new throwout bearing
>new clutch slave
>"new" LT230 later suffix
>new ashcroft input gear set for LT230
>3x GKN joints, still got the rubber donut, did that one new a few months back
>every electrical switch related to this work was swapped out, so reverse lamps work, diff lock light now works!
>new starter wire (old one was routed wrong?, pretty baked by exhaust)
>new rear axle brake lines
>new brake master
>all brake lines bled

Sure I am missing an item or two, will correct.

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>Found a tire close enough to the pizza cutter size and fit it on a spare wheel lying around.
>popped a new fan clutch on, for the first time in over a year you can hear the motor itself, not just the turbofan vacuum cleaner sound of doom

39476891541_d21d8a2b9c_k.jpg

Need to print an idiot sticker showing which way the fan comes off, took a while to figure out it was opposite the tdi one.

39476895061_845009d4e9_k.jpg


Shifts super nice now.
 
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DiscoDavis

Explorer
Awesome! Keep up the good work. Love these D1s

Thanks! Still at it... always something to do next

Love the dixon-bate!

This truck soooo needs 245/75/16 KM2s!

Sadly only the 2 tonne model! Whenever I find another 5 tonne and find some plate to reinforce the bumper it will be camel spec. And I wanted to keep with the 205 85's but nobody makes a decent tire that's reasonably available... I hear duratracs are in 215 85 so will try those... ;)

Better pic from covfefe shop today
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A.J.M

Explorer
That cars had some serious work to it.

Now get the underside treated to preserve it.
I do love a clean unmolested D1. Such a simple design to it.

For this car, personally the “less of more” approach is how I would go.
 

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