2000 Disco II Major Rebuild/Overhaul by RSPTex

4 minute(s) of a 50 minute read

I've got a new t-case on the way and I'm rebuilding the transmission myself this week while I wait for crank bearings from England.

But I agree, this sucker was limping on its last polio-ridden leg. Just about everything that moves is getting replaced, rebuilt, or serviced.

9-3-2014

Time for an update!

I finally have the last parts I need ordered for the engine, transmission, and transfer case rebuilds. The engine rebuild will go way fast, especially given all of the new parts and freshly machined everything!

I was able to take the transmission apart and lost a few very small pieces. I'm headed to a transmission shop to see if they carry the spares. It's the two check ***** and the dimple-shaped check valves in the valve body. I am having trouble finding a good manual to show the proper rebuild procedure for our 4hp22/24's. Plenty of others floating around, though. And the one I'm using can be found in the google drive folder I linked to a few posts back. The only real assembly trouble I've had is knowing how many of each of the layers of metal/textured clutch plates to use and also getting the entire assembly to fit back into the transmission housing. I have it within a 1/4" of fitting under the snap ring. I know that means something isn't engaging or I did something wrong, but I don't know where, yet. The other trouble was trying to replace the bearing of the oil pump. The kit from Rock Auto came with that bearing, but trying to put it in is crazy hard unless using a bearing press. I also found out the rear seal that comes with the Rock Auto kit is useless. It was made for a RWD output adapter, not like ours. The part we need is RTC4650.  


The new transfer case is in and I've cleaned it up and I'm waiting on the gasket and seal kit (and bearings) from England before I rip it apart and reseal it with new bearings. The transfer case looks good. But then again, anything looks better than my old one...

While waiting for parts, I've taken the bumper off to repaint it and also do my headlight conversion. Don't let anyone tell you the sheet metal comes off easy. It's a huge PITA!

And after removing it, I have no clue where to make new mounts or how to mount the new headlights. All I know now is that I'm going to make custom mounts with some threaded rod. I'll use 3 rods per headlight and secure them to the headlight with RTV sealed mounts. I'll also have to figure out mild shock-absorbtion. There are plenty of write-ups on the conversion, but so few on how to secure the headlight after gutting the old mounts. I think that will be one of my contributions to this community. I'll put that together with photos in a separate thread.

The bumper was rusting much more than I thought it was. I sanded it down and chipped away as much rust as possible. I then covered the ARB emblem with tape, and put a few coats of the "Rust Reformer" by rustoleum on it. According to them, it converts the rust to a paintable and primed surface. I'll coat it a few more times with some matte high performance enamel and then a coat or two of the glossy high performance enamel. I'll have it done this evening. Here's a pic of where it's at now: