Notes on All in One Installation
I am finally driving my Rover again after lots of hook up work. Its good timing with the first snow of the year. It runs pretty well considering how much was taken apart / swapped / or rebuilt. I still have some CELs to work out, but until I get the adaptive values reset with a test book this week - I don't think things can't be diagnosed further since all sensors are new including TPS.
Anyway, a few notes on the installation should anyone be looking at doing this job.
1. Putting the engine and transmission in together with out the transfer case was the easiest part, but some considerations to remember.
2. The transfer case is a monster so lots of help, transmission jack, or LR adapter plate for lift would all be helpful. I ended up setting the TC in with my legs up under the car just to keep things lined up. This is much easier without any of the Emergency brake installed. I wish that it could all be installed in one piece (meaning with TC attached to back of tranny), but that was not going to happen. I saved by putting the engine and transmission in together, but the TC took most of an afternoon and lots of wheaties.
3. Before you tilt the assembly back up to level you can install the TC shift linkage under the car (no radiator or fan installed yet). This was pretty easy if you can get up above the TC with your head to see what you are doing. Make sure it all works and grease those joints well as that is what locks up often.
4. Get all your wiring harness connectors installed and ready for the 02 sensors before you install the exhaust or tilt the transmission back up.
5. Don't forget the front bolt on the Transfer case. It can be installed after the fact, but that is not as much fun with the driveshafts installed.
6. Don't forget the two wire connections for the diff-lock sensor on top of the TC by the shift linkage attachment points. Not fun after the fact.
6. Install the Emergency brake, cables and adjust after the TC is mounted. It helps to go ahead and adjust the emergency brake now while the driveshafts are off. This takes two people, one for inside the car.
7. Install the crossmember and exhaust only after you know everything is all wired up and you have changed your transmission filter. Now is the time to do that if you have not already.
Overall, its a big job because the parts are so heavy and cumbersome, but there is plenty of room and it can be done in a garage with just floor jacks.
I may have another troubleshooting post for idle speed issues if I don't get those worked out. But at least it is back on the road.
I may be parting with the spare TC and transmission that were working (210k miles) once this swap has proved itself - I am here in Asheville NC if anyone might be interested. I have a few decent parts (brush bar, front bumper)
It ain't easy being green.
97' Disco SE6 (that is a joke - I just added 1 seat for kid #3)
09 Civic Si Sedan