2000 Disco II Major Rebuild/Overhaul by RSPTex

6 minute(s) of a 50 minute read

For anyone keeping up with this thread, here's an update.

I have the engine, transmission, and transfer case in.  Engine is doing well. It sounds great and hasn't had any issues except for the front O2 sensors that aren't sending a signal. I had a bit of an overheating issue, but I was also using the old thermostat that wasn't opening. After installing a new one, it's as happy as it can be. I've adjusted the throttle and cruise control cables to the spec in RAVE, but after the truck warms up, the idle drops gradually from 1k to .5k. It takes about 5 minutes to do it. While warming up, though it idles at 1.1-1.2k. I'm guessing the low idle speed is due to the lack of feedback from the O2 sensors. I'll run new wires to them later this week.

I installed Magnaflow cats and a custom magna flow muffler with the resonator removed. To make sure it gets nice cold air, I have a snorkel coupled with a K&N air filter. I bought a cheap snorkel kit on eBay for $180, and it didn't have the best instructions, just a template. I had to figure out where to cut the holes to make it fit correctly. I used a lot of RTV to seal all the joints and the air box. I also had to rebuild the connection between the air box and the fender. When cleaning it, a pressure washer was used. The fabric disintegrated. It's fine, now, and sealed up nice and happy! The truck breathes well.

As you can see in prior posts, the original transfer case was shot, so I bought another and resealed it as well as well as replaced the bearings. It's in generally good condition. I bought a CDL kit from Abran and was going to put it on my old transfer case, but now it's on the new one. I only had one issue with the transfer case. When I tried to shift the transfer case into hi or low, I couldn't. It was the lockout solenoid that I put in from the old D1 transfer case that was in there before. I tossed it, and now it works fine.

I have an early D1 rear driveshaft instead of the rotoflex one. The front and rear driveshafts are rebuilt. New U-joints and centering ball kit. the front driveshaft came front Dusty1. Huge help.

Power steering fluid is replaced and happy.  Brakes are, too. I put new rotors, pads, and longer stainless lines on. It will be able to stop! I do these projects after school and work, which sometimes means doing work in the rain at night... Good thing I work for a company that does portable emergency power!


Because I wanted a fun look, I bought 18" mondial rims and some 33" tires. I'm using 1.5" hub-centric spacers to give it a wider stance, too.


The transmission is not playing nice with me, though, and I think I know why. I think I need to add more transmission fluid. I've added it until it runs out of the fill hole while in park and neutral, but not drive, reverse, or 1,2,3. I still need to add that, and it could be the cause of the issue, but more likely it's the XYZ switch needing to be serviced and repositioned.  
This is why:
-Cannot get the dash or gear selector to tell me I'm in 1st,when the gear selector is put in 1st and the selector on the transmission is definitely in 1st.
-Reverse is the only gear that works. 1,2,3, and D do not work.
-When trying to drive, the "M" and "S" start flashing, with the D on the gear selector.
-Just started getting a P0722 code
-Also, it feels like if the transmission had a hand, it'd be flipping me off

Aside from the major stuff, I still need to do a few smaller things. I need to run lines to the washer jets of the bumperand the hood. I have new jets for the hood. I also need to do the wiring for the 03-04 headlights. The spots are prepared and the mounts are made, I just need to do the wiring. The hood is also repainted with mixed results... You can read more about it in the thread I put up about it.



On a more fun note, I have a custom roof rack being made! There's a guy a few hours north of here making it for me and also powder coating it and my rims. The roof rack is all aluminum, and has a few fun perks. I designed the rack in CAD. It won't block any sight through either of the sunroofs. It has a removable insert to make it compatible with a roof tent. It also has two skids that slide out from the back that are very grippy, and will help get me out of snow, mud, ice, etc. Lastly, there are LED bars facing every direction that are built into the rack. One very large one on the front, and 3 large ones facing the sides and rear. I figure I'll need to be able to see the zombies coming from any direction in the apocalypse. And as if that weren't enough, I also have 4 flood lights mounted on the front of the ARB bumper. With the rack and wheels, I feel like this truck is going to look pretty Bad-A.


Now if I can just get it to move forward under its' own power...

Also, if anyone wants the CAD files for the rack, let me know, I'll be happy to shoot them over to you. My only condition is that you don't use them to make money.