Defender 2.5 NA to 300TDI conversion - Defender Source
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Old January 28th, 2014, 04:05 AM
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1992/Defender 90, 1994 Defender 110
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Thumbs down Defender 2.5 NA to 300TDI conversion


Maybe this question was asked 100 times but please answer me one more, cause i couldn't find exact answers.

I have Defender 110 with 2.5 NA engine, i don't know what's the gearbox, it has reverse gear near to 1st, and i am going to buy a Discovery I with TDI engine and swap the engine, power steering and Air Conditioning,

Firs question is will the 300TDi fit my gearbox, if not what could be the solution, as i know discovery gearbox has the stick on the wrong place for the defender. what else should i know about the swapping the engine?

How hard is to retrofit the AC in Defender, is it possible at all?

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Old January 28th, 2014, 07:28 AM
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Capt Milks
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Defender V-8, Defender 2.25
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What transmission does the Discovery have?

The A/c in a Disco is completely different on the inside of the truck. You may be able to use the compressor and the condenser however. Some people have used the aftermarket stand alone systems that you can find in Hot Rods.

The Disco Radiator is also different. The Defenders use a Radiator with the intercooler right next to it. You can purchase a different intercooler and run it in front of the radiator but that may get in the way of the A/c stuff.

Is the Motor in the Disco a Disco motor. The Exhaust and turbo locations are different than the Defenders if it is.

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Old January 28th, 2014, 08:43 AM
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Uncle Douglas
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Doug Crowther
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There is no difference between a disco 300 and defender 300 engine except the air filter assembly's, You can change a disco r380 to defender configuration by changing the shift tower and the top cover plate below the shift tower,
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Old January 28th, 2014, 09:00 AM
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John B.
1991 Defender 90, 200TDI
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But changing the shifter also means opening op the box and changing some internals, correct?

I would suggest doing some Google searching first. There are many writeups out there on conversions.

It is possible to use the existing gearbox. Depending on the suffix of the box there can be strength concerns. It is also more complicated to use the short bellhousing.
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Old January 28th, 2014, 11:07 AM
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Michael White
110 Tdi
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Location: Dripping Springs, Texas
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Your gearbox is probably an LT77, which is what I had mated to my 300 Tdi. It will fit, but the 300 Tdi will sit an inch or two further back than usual. This makes things a bit tight when needing to repair anything at the rear of the engine. It also means you'll need to have custom oil cooler and A/C lines made as they need to be a couple of inches longer - don't do what the previous owner of my truck did and slice & splice, as they will leak.

I've heard the early LT77s are weak, but I never had an issue with mine. I got rid of mine due seal leakage between the case components and figured it wasn't worth rebuilding. I actually prefer having first next to reverse, though.

The only real down side is if you ever decide (or need) to upgrade to an R380, then you'll need to move the engine mounts forward or buy a more expensive stubby R380. I ended up buying the stubby R380.
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