Just a quick couple of photos to show the Borg Warner transfer box and the torque converter housing (to take the  place of the existing flywheel housing) to mate the ZF auto box to the 200Tdi.
The Borg Warner unit has the same low ratio as any LT230, but has the 1.22 hi range ratio used on most RRCs and Discovery Is. Â Unlike the LT230 or the Series transfer box, it uses epicyclic reduction gears for low range, that set being locked for high range, and the output of that gear set is connected to the output shaft by a chain, so it is much quieter. Â It has a centre diff like the LT230, but that has a viscous coupling on the front output shaft to make is function as a limited slip diff, so there is no diff lock control.
The torque converter housing is much thinner than the manual flywheel housing. Â That is important for correct alignment of the torque converter. Â It’ll also help save a little space during the conversion – the ZF box is much longer than a Series box, so the engine and transmission will be a tight fit between the 2nd and 5th cross embers (the one with the steering relay and the one behind the transmission).
Hi Nick ,it is nice see same one do same things as me , I also did conversion of my 2a 109 NADA to V8 4.0L Gem engine and auto transmission plus coil springs, axles from Discovery and more room for my 6 feet body to fit in series 2a. Well took me 3 years to complete this , but is now fan driving this truck . Well Land Rover make this trucks be customized for need of owners and we do that.
The definition of insanity Nick…doing the same thing over and over and expecting different results!
Reading back regarding your previous posts on transmissions, what is blindingly obvious is that both the LT76 and the god awful (I read lRO international columnist with a series conversion who has had the £2000 unit fail again and again) and expensive (ludicrous) overdrive from canada are never going to bear up under the pressure of the 200tdi which punches harder than a Mike Tyson Thouroughbred hybrid.
You need an LT77 or a stumpy R380 to overcome this saga finally, but you got to ask yourself, apart from the mine of info and experience you have gained, is it worth it? I would have thrown the towel in long ago for a divorce, superbike and a couple of years living somewhere hot! Probably cheaper and a heap less agro.
Nothing insane about it if you can learn the causes and make progress. There are a lot of entries on this blog about the gear box because I had several unrelated issues: the jumping out of fourth, which was due to an incorrect input pinion; broken leaf springs on the 3rd/4th synchro, which is a common affliction from wear, and; the breaking of 3rd gear due to a combination of overdrive and taller diff ratios, cured successfully by removing one of the gearing increases. There were good reasons not to go to a later transmission, including the avoidance of an IVA, reregistration and subsequent road tax.
As for the overdrive, the only time it had a failure was due to the severe oil leak from the transfer box causing it to run dry. I rather suspect the Saville’s SI unit may have been subject to some similar events or some other problem to have needed three rebuilds.
The Series transmission was not designed for the torque of a Tdi, but it does cope well as long as you don’t overdo the resistance downstream of it with excessive gearing, be that combinations of overdrive, HRTC, diffs or taller tyres. I and a few others have learned that the hard way, but now the knowledge of where the line is, that can be shared and others can have equally reliable vehicles without the expense and difficulty of fitting the later transmission. That is still a good option for many, and I’d be considering it if the DVLA regulations wouldn’t have negative consequences in this case.
As for living somewhere hot, I currently do, and with temperatures over 45 degrees for eight months a year and humidity often well over 90%, it’s less fun than you might think.
Would anyone happen to know the Part Number of the 200tdi Discovery ZF automatic Flywheel Back plate Pictured in this posting.
Thank you for any info that can be provided