summer project lots of ???

[96owner]

Ok so schools out finally and I have 3 months of nothing to do. So before i start my sophomore year I want to make my rover look like a totally different truck. Or at least make it run like new. So my truck is a 96 disco 5 speed.
First off I would like to know what I should check out? I got the gas tank recall done with a new fuel pump and I think they replaced the fuel filter with too. I’m going to replace all the fluids and such and maybe do a top-end rebuild and replace all the gaskets. So question 1 is any tips of what I should check out while I’m in the process or working on the truck?

Second I want to lift the truck 2 or 3 inches. I’m thinking a RTE kit. The truck will see mostly road time but as much off road time as it can. Also how big can I go with tire choices? And will there be a lot of sag over time and how good do the springs and such hold up to corrosion? And is there anything that should be looked at before I lift it.

Now to my biggest problem I have leaks. So I’m going to try and replace most of the weather seals on the truck. But the carpets are wet and there is some rust and a rust hole under the rear seat. I’m thinking about just sanding it out bondoing it up and then spraying over it with some rust proof krylon. But besides that rust what are the chances that there is some more. I’m going to rip up all the carpet so check it all out but what are the chances there will be a lot of frame rust and how would I go about fixing all of it.

And to end to summer out I want to repaint the truck. I’m thinking about keeping the same colors it is now but just a full truck respray. So has any 1 done anything like this or has any tips for going about this? Well I have full summer ahead of me so I thank every 1 very for any help you offer.
And if I’m unclear about anything just ask and I will try to better explain my goals

[keptin]

not sure about the technical end of DIs, but I do know that if you go with the RTE 2" lift (netted close to 3"), then you may risk driveshaft issues if you have driveshafts with rotoflex couplings.


oh, btw:

[llesra]

3" rte springs need new drive shafts! 2" would probably be best. you might also want new shocks to go with those and extended brake lines so the stock ones dont snap. a good tire size to go with is 265/75/16. anything bigger would make your disco even slower and breaking axle shafts can happen so much easier.

[VArova87]

how many miles?

[me.guevara]

Instead of repainting the outside, given the issues we face with water intrusion and rust, I would recommend stripping out the inside, getting rid of the rust/patching the gaps and waterproofing it - I went for the Rhino Liner - now I don't care if anything leaks (or is someone spills their juice)...

While you're doing all that work, you may want to consider checking out the ignition system: battery, coil, ht leads and plugs - replace them with aftermarket HD parts and you'll notice the results.

If your rig has the original alternator, you may want to take a close look at it, the belt and tensioner, too (while you're at it).

Clean your MAF sensor (carefuly) and change your O2 sensors.

I envy you. Have fun!

[Capt. Ron]

School's out!

Chances are you'll find rust everywhere. If it's had time to eat through under your seat, it's had time to eat through in other places. Remedy that first, if it's worth it, and not with bondo. Have a body shop weld in replacement aluminum. I think tackling this first will give you an idea of what it's worth to spend money on.

There is so much info on tires and springs. Each truck is different. Search the site here for opinions. A 2" lift on one does not act like a 2" lift on another. Anything over 2" will more than likely necessitate other mods, ie. pinion agles, handling issues (steering geometry) etc. I have a 2" OME, heavy duty shocks. I had 265/ 75 MT/R's, rough ride. No acceleration or top speed. But looked great.

Why are you doing a top end re-build? If it doesn't need it, wait. On the other hand it's your truck.

[96owner]

Originally Posted by VArova87

how many miles?

250,000 i think. and no matter what poeple tell me its not worth it on a lod truck i think it is it has meaning to me hard to explain. and poeple have told me it runs better then any other disco they driven.
and welding in new panles well i know some poeple with sme welding skills so could i sand out all the rust and patch it up or... i realy have no clue how im going to go about this project so i need to start researching now.

[VArova87]

with 250k i would def make the engine a big priority...having a rover that looks personalized, but if it wont run, you'll have to invite your friends over to watch it sit. make sure you replace everything under that hood that could have gone bad...have you done o2 sensors in awhile? i would also suggest getting all new hoses, filters, etc... DAP can help you out there. also, have you done anything to the exhaust? I'm at 117k miles and my muffler and one cat are already rusting out. chances are of you havent touched your exhaust, its time for some new parts. look at getting a set of headers too. LRs are good at leaking around the manifolds. Headman has a set that will fit with some work, or if you have the money, Janspeed has a set for around $475. Also, if you have your stock suspension, a new suspension would be critical. You might have a little sag in your springs and maybe even a busted shock at 250k. Lift it while you are at it, its not any more expensive to do so. Big Blue has a set of springs, go with some Bilstein shocks. DAP can help you out there, too. (Talk to Steve about all of your needs, he will get the ball rolling for you) Once again, make sure you get the engine and drivetrain up to speed before you start dumping money into a paint job and "pretty" stuff.