D90 LS3/6L80 Conversion - Defender Source
Defender Source  

Go Back   Defender Source > Build-up's, Projects & Registry Profiles > Truck Build-up's & Restores


Reply
 
Thread Tools
  #1  
Old June 1st, 2017, 12:51 PM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
D90 LS3/6L80 Conversion

Meet Vizzini. 1988 ROW LHD 90 from Sicily. 19J, 5spd, 70k KM, no rust, new paint and basic interior. I bought him because the seats match my boots. Perfect for Texas!

Actually, I was looking for a solid truck that had the right look, but needed mechanical work. I also have two other LRs that play utilitarian roles. My S3 109 (Montoya) ferries guests from the train station to our home in NY and regularly makes local trips to farmers markets and other wifey requirements. Fezzik is pure off-road fun with a 2" lift and a power upgrade.

Given Vizzini will be mainly highway, urban and only light off-road work (traversing the in-laws Texas ranch and Cibolo creek access for creek "sit and drink" parties), he is more built for speed. So far, I've:

1. Lowered him 2" with new 2" lowering springs
2. Replaced the shocks and stabilizer with Bilsteins
3. Replaced the steps with side bars and step bumper
4. Replaced the stock wheels with 18x8 alloy saw tooths and BFG 285/65R-18 KO2 tires
5. Made a few other cosmetic changes that fit with my style better

Plans are to replace the 19J diesel with an LS3/6L80 from a 2012 Camaro. I just bought the drive train, Nicks adapter, motor mounts, brackets, etc. and will start the conversion once the drivetrain arrives. This thread will be my documentation of the build. Here are some pics:
Attached Thumbnails
Click image for larger version

Name:	IMG_0857.jpg
Views:	123
Size:	209.8 KB
ID:	250290   Click image for larger version

Name:	IMG_0919.jpg
Views:	121
Size:	174.2 KB
ID:	250298  

Click image for larger version

Name:	IMG_0925.jpg
Views:	133
Size:	262.7 KB
ID:	250306   Click image for larger version

Name:	IMG_0915.jpg
Views:	132
Size:	196.4 KB
ID:	250314  

Click image for larger version

Name:	IMG_0927.jpg
Views:	127
Size:	210.6 KB
ID:	250322  
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
Sponsored Links
Advertisement
 
  #2  
Old June 1st, 2017, 12:57 PM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
Here are a couple shots of the springs/shocks:
Attached Thumbnails
Click image for larger version

Name:	IMG_0905.jpg
Views:	111
Size:	185.0 KB
ID:	250346   Click image for larger version

Name:	IMG_0906.jpg
Views:	107
Size:	147.2 KB
ID:	250354  

Click image for larger version

Name:	IMG_0907.jpg
Views:	110
Size:	172.8 KB
ID:	250362   Click image for larger version

Name:	IMG_0911.jpg
Views:	112
Size:	207.4 KB
ID:	250370  

Click image for larger version

Name:	IMG_0913.jpg
Views:	120
Size:	172.8 KB
ID:	250378  
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #3  
Old June 8th, 2017, 10:04 PM
Brewie212's Avatar
Brewie212
Status: Offline
Brian Kandefer
1957 107 wagon, 94 arles St, 101 FC
Member
 
Join Date: Jul 2012
Location: NC
Posts: 3,145
Be careful before you drive it, you are gonna have to shave the bellhousing to clearance the front driveshaft.
__________________
"Someone once told me not to bite off more than I can chew, I told them I'd rather choke on greatness than nibble on mediocrity!!!"
Reply With Quote
Sponsored Links
Advertisement
 
  #4  
Old June 9th, 2017, 03:12 PM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
Thanks, Brian, I'll check it carefully. Particularly since it is lowered. I know the 4L80 has clearance issues, but the 6L80 (completely different design) is thinner and I didn't think there would be interference issues. I'll inspect it before I drive it.
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #5  
Old June 9th, 2017, 04:33 PM
Brewie212's Avatar
Brewie212
Status: Offline
Brian Kandefer
1957 107 wagon, 94 arles St, 101 FC
Member
 
Join Date: Jul 2012
Location: NC
Posts: 3,145
The driveshaft hits the oil pan casting and also on the trans bell housing. We lowered two trucks and both had six speeds so just be careful
__________________
"Someone once told me not to bite off more than I can chew, I told them I'd rather choke on greatness than nibble on mediocrity!!!"
Reply With Quote
  #6  
Old June 12th, 2017, 08:04 PM
spikemd
Status: Offline
Ted
2001 P38, 2006 LR3, 1991 109
Member
 
Join Date: Jun 2010
Location: Sacratomato
Posts: 63
Nice, clean truck. Love the PB references!
Reply With Quote
  #7  
Old June 12th, 2017, 11:03 PM
MCMLXIX's Avatar
MCMLXIX
Status: Offline
Rich
None
Member
 
Join Date: Mar 2017
Location: Las Vegas, NV
Posts: 141
... as you wish ...



Are you doing the swap or having a shop do it? NY or TX?
Are you going with a Lokar shifter to keep the stock look?
Reply With Quote
  #8  
Old June 13th, 2017, 09:32 AM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
lol, thank my daughter. She named the 109 "Montoya" as it is a Santana from Spain.

Vizzini just made sense as it is Sicilian and will have a brain (ecu).

Fezzik is special to me as my wife bought it for me when we lived in London and we had to sell it when she became ill. After she passed, I managed to find it again in the U.S. earlier this year.

There will be no Buttercup!
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #9  
Old June 17th, 2017, 10:04 AM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
Finished up the exterior lighting and some cosmetics. He's heading to the inspection station and Texas registration next week!

I've figured out my fuel and cooling systems for the LS3 upgrade. Pictures on that will follow. I was thrilled when I inspected my fuel tank and discovered it had a welded in baffle or fuel pump well already from the factory. Makes things much easier.
Attached Thumbnails
Click image for larger version

Name:	IMG_3405.jpg
Views:	65
Size:	249.1 KB
ID:	258122   Click image for larger version

Name:	IMG_3404.jpg
Views:	70
Size:	291.6 KB
ID:	258130  

Click image for larger version

Name:	IMG_3403.jpg
Views:	69
Size:	329.5 KB
ID:	258138  
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #10  
Old June 17th, 2017, 10:10 AM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
Oh sorry, Rich, missed your questions. I'm doing the swap myself here in TX. I'll be using a Lokar shifter with a brushed aluminum 5sp knob both so I can keep my custom shifter gator and just to be different.
Attached Thumbnails
Click image for larger version

Name:	IMG_0915.jpg
Views:	80
Size:	196.4 KB
ID:	258154  
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #11  
Old June 20th, 2017, 04:46 PM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
I worked up a step-by-step list for this conversion. I plan on documenting it here just because it is fun and someone might benefit. I usually benefit the most from my mistakes along the way, so perhaps this will help others.

Here is my checklist. I used Nick's list in the adapter thread and built on it. I'll reference this list by step number along the way and I'd love any suggestions or changes you see if you take the time to read through all of it. This is for my conversion of a 1988 D90 with a turbo diesel (19J) and LT77 to an L99/6L80 from a 20k mile 2012 Camaro.

Some install tips and order:
1. Disconnect the negative battery cable, remove the hood and front grill. Drain and remove the radiator, surge tank and all brackets. Capture all fasteners and small parts in ziplock bags labeled with a sharpie.

2. Disconnect the prop. shafts, e-brake cable, speedometer cable, throttle cable and all electrical connections, carefully labeling each wire with masking tape. Disconnect and drain the clutch master cylinder at the slave. Once drained, seal the slave. Clutch fluid will remove paint almost immediately!

3. Drain and disconnect the power steering reservoir and pump, sealing all pump connections.

4. Disconnect the fuel supply and return lines at the lift pump and remove the firewall mounted filter, lines and fuel tank.

5. Connect an engine hoist with an engine leveler to the engine and ensure it is properly connected to four SECURE points, two on the front and two on the rear of the engine. Adjust the leveler so that the engine hoist lifting hook is as close to the rear of the engine as possible and use the hoist to take all the slack out of the leveler lifting chains. Remove the crossmember and unbolt the four mounts holding the engine and transmission to the chassis. A floor jack may be helpful in lifting the transmission enough to clear the mounts until you can move the whole assembly forward with the hoist. Remove the engine and transmission as a unit.

6. Remove the steering box and rebuild or replace as required, reinstalling a leak free unit (you know the original has leaked for years!) after step #7.

7. Inspect the engine bay, removing any items not required (old mounts, brackets, diesel components, clutch master and pedal, etc.). Weld in the new frame motor mounts, clean the engine bay, install the clutch block off plate and prime/paint as required. Now is the time to make it spiffy!

8. Remove the exhaust manifolds from the LS3. You will end up slamming them into the steering linkage on the way in. It also gives you access to the engine mounts. The stock exhaust manifolds are discarded.

9. Remove the intake manifold. It needs to be rotated 180 degrees anyway. Too much risk of getting damaged. NOTE: Not if LS3 donor from car.

10. Remove any shifter linkage (transfer case and transmission) These can be installed from the tunnel opening.

11. Install the harness on the engine and connect the transmission connector prior to bolting up the LT230. The transfer case traps the transmission electrical connector.

12. Leave the engine mounts (Energy Suspension and aluminum plate) loose to allow alignment.

13. Leave the power steering pump off until engine has been installed. Too much risk smashing it on the steering box.

14. Install the adapter onto the transmission first. Then the LT230 onto the adapter. Don't forget the two alignment dowels between the adapter and LT230. Also, the two 40mm bolts need sealant as they are open to gear oil. The tail housing is dry, so no gaskets required there. Good time to install a new input shaft seal in the LT230.

15. If possible, drop in the engine/transmission/LT230 in one shot. Else, engine/transmission in one shot.

16. Level the engine and bolt the engine, TC, and adapter frame mounts to torque spec. Bolt up the prop. shafts and check for clearance (in a lowered vehicle, the best approach is to disconnect the front prop. shaft at the differential and move it up and down through the normal arc travelled during suspension movement to ensure clearance). Adjust or trim any obstacles such as the transmission bell housing and oil pan. Install the motor mount heat shields.

17. Reinstall or fabricate as required a new crossmember. If fabricating, adjust as required to optimize exhaust routing (step 19).

18. Install the modified fuel tank with in tank pump and new sender. Install filter/regulator on firewall, fabricate twist lock hoses and install supply, return and fuel rail feed. Secure all fuel lines safely, shielding from heat and any potential debris from the wheels.

19. Install headers and fabricate the exhaust system, carefully removing or isolating any electronics (ecu, etc) before welding. Tack on the car and remove each section for final welding, reinstalling each section after final welding to ensure proper fit.

20. Connect the Speartech modified harness connections, install fuses and relay, and connect to vehicle electrical system as required.

21. Configure accessory brackets, alternator, PS pump and A/C compressor as required to clear chassis, install and tension belt. Connect lines to power steering pump, reservoir, and steering box.

22. Install radiator, fan(s) and surge tank, fabricate and install all hoses to radiator, surge tank and heater ensuring all fittings and clamps are tight. Install the intake hose and filter, refitting the MAF sensor.

23. Install transmission cooler and run lines to transmission, securing them and shielding from any hazards.

24. Install A/C condenser and connect all A/C lines.

25. Install shifter, TC linkage and new gauges.

26. Double check everything!

27. Fill all fluids, bleed cooling system, reconnect negative cable, look for smoke (hey, it still has some Lucas components), and start the engine. NOTE: my wife now requires all first starts to happen outside the garage. Ever since the engine in the Cobra shot a fireball out of the carburetor due to the distributor being installed 180 out. Oops. For the record, it was a small fireball.

28. Take a short test drive before reinstalling the tunnel, hood, and other body parts removed for the conversion. Check for leaks, rubbing, and all other paranoid concerns created by a conversion of this magnitude.

29. Drink.

30. Well, that's all there is to it. A weekends worth of work...okay, so probably 100 hours if you are a reasonable shade tree, have the right parts and tools when you need them and don't get interrupted too many times or suffer from "whileIwasinthere" syndrome.
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #12  
Old June 20th, 2017, 05:07 PM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
Wow! That was a lot of words. Here's a couple pics of the Cobra with the wife just to break the monotony.
Attached Thumbnails
Click image for larger version

Name:	IMG_0939.JPG
Views:	140
Size:	157.9 KB
ID:	259498   Click image for larger version

Name:	IMG_0940.JPG
Views:	91
Size:	135.7 KB
ID:	259506  

__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #13  
Old June 21st, 2017, 11:55 AM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
Just waiting on the tank six hole gasket to complete my LS tank set up. I used a stock sender with the low fuel light and a Tanks fuel pump set up that includes the correct Walbro pump. Just have to trim the supply side to length and it is ready to go. I did have to redrill the tank for the six hole mount vs. the standard five hole, but no big deal. Gasket should be here Friday. I have a feeling lack of parts will delay me more than anything else.
Attached Thumbnails
Click image for larger version

Name:	IMG_3414.jpg
Views:	58
Size:	36.8 KB
ID:	259714   Click image for larger version

Name:	IMG_3415.jpg
Views:	64
Size:	95.9 KB
ID:	259722  

Click image for larger version

Name:	IMG_3416.jpg
Views:	57
Size:	69.0 KB
ID:	259730   Click image for larger version

Name:	IMG_3417.jpg
Views:	59
Size:	116.8 KB
ID:	259738  

Click image for larger version

Name:	IMG_3418.jpg
Views:	53
Size:	60.4 KB
ID:	259746   Click image for larger version

Name:	IMG_3419.jpg
Views:	50
Size:	53.2 KB
ID:	259754  

Click image for larger version

Name:	IMG_3421.jpg
Views:	49
Size:	74.5 KB
ID:	259762  
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #14  
Old June 21st, 2017, 12:52 PM
phoenix37's Avatar
phoenix37
Status: Online
john
97 D90 ST / 1957 S1 109/ 1983 LS110
Member
 
Join Date: Feb 2008
Location: Venice, CA/Yarmouth,ME
Posts: 5,557
Registry
Love the Cobra... and congrats i can't say I've ever seen my wife smile when she comes in the garage and sees an engine on the hoist ...
Reply With Quote
  #15  
Old June 21st, 2017, 02:16 PM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
Thanks, John!

You can imagine my concern at hoisting that small block 427 and tko600 over that beautiful aluminum coach work. There was a large pucker factor which I believe is what she was smiling about. She barely tolerates all my cars (currently 7) I sold the Cobra and bought the 904. She is happy when they go and irritated when they arrive. I don't even tell her anymore, just share the balance sheet, keeping the tally positive since I met her. Hard to argue with that!
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #16  
Old June 24th, 2017, 02:46 PM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
Got the gasket today (got to love Summit) and finished up the tank. I used the old hammer and blade trick on the sender locking ring.

The engine/tranny should be here this week. I have to clean out the garage and make a space for the 90. I'd like to get started in early July. My goal is to finish in a month which means it should be just about finished by 2018.
Attached Thumbnails
Click image for larger version

Name:	IMG_0944.jpg
Views:	44
Size:	102.1 KB
ID:	261506   Click image for larger version

Name:	IMG_0945.jpg
Views:	52
Size:	99.3 KB
ID:	261514  

__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #17  
Old June 28th, 2017, 02:23 PM
Factoid's Avatar
Factoid
Status: Online
Mark
Three criminals seeking revenge
Member
 
Join Date: Mar 2017
Location: San Antonio, TX/Putnam Valley, NY
Posts: 438
Registry
It's a glorious day here in San Antonio!

My 20k mile 2012 Camaro drivetrain showed up. I had to park it behind the 904 until I can get the middle bay cleaned out and the defender backed in. I have a bunch of work to do before I'm ready anyway. First up is removing the wiring harness for a trip north, swapping out the oil pan, changing the tranny to 4wd and tearing down the engine to be ready for the install.

Most important, it arrived safely!
Attached Thumbnails
Click image for larger version

Name:	IMG_3437.jpg
Views:	67
Size:	231.2 KB
ID:	263138  
__________________
1976 Series III 109 "Montoya" ("You killed my father, prepare to die")
1988 Defender 90 LHD "Vizzini" (speed demon from Sicily)
1987 Defender 90 MOD LHD "fezzik" (giant rock thrower)
2015 MB CLS63
1975 Porsche 911 hot rod
1964 Porsche (Beck) 904
Reply With Quote
  #18  
Old June 28th, 2017, 02:38 PM
speedpin's Avatar
speedpin
Status: Offline
Adam
1985 130 Gen IV
Member
 
Join Date: May 2010
Location: Fredericksburg, VA
Posts: 2,183
Registry
Wow! let the fun begin
__________________
~ Semper Fidelis ~
Reply With Quote
  #19  
Old June 28th, 2017, 02:48 PM
SLO Hybrid's Avatar
SLO Hybrid
Status: Offline
Nathan Harrison
95 25th RRC/94 LWB /04 L322/87 RRC
Member
 
Join Date: Jun 2005
Location: Atascadero,CA USA
Posts: 68
Let me guess you have a 993 motor in the 904 too
Reply With Quote
  #20  
Old June 28th, 2017, 02:50 PM
Rocky's Avatar
Rocky
Status: Offline
Chris
72 + D1 drivetrain
Member
 
Join Date: Sep 2006
Location: Colonies Aka Boston
Posts: 8,575
Texas huh? Time to add Air Conditioning!
Reply With Quote
Reply

Lower Navigation
Go Back   Defender Source > Build-up's, Projects & Registry Profiles > Truck Build-up's & Restores

Tags
90, conversion, d90

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
94 D90 wagon, 300tdi for sale Chris Cox For Sale - Vehicles 20 November 9th, 2005 11:43 AM
95 D90! TwisteD90 For Sale - Vehicles 30 September 14th, 2005 01:54 AM
Advice on buying my first D90 mtbrooks Defender Technical Discussions 7 July 19th, 2005 06:48 PM
D90 won't start! rover4x4 Defender Technical Discussions 32 June 13th, 2005 07:42 AM
poor gas milage / blown head gasket? got a read diff for a 94 D90? rover_rich_d90 Defender Technical Discussions 7 April 20th, 2004 02:11 PM


All times are GMT -5. The time now is 03:03 PM.


Copyright