Land Rover Discovery 2 - A nearly complete build

[Jeff Blake]

A bit late to the party here... but here she is. I've tried to list out all the mods I could remember below.

Photo album: https://www.flickr.com/photos/14372317@N07/albums/72157688130082804




2002 Discovery 2.

Purchased @ 106k miles. Currently 108k on the clock. Everything has been redone, more or less, except for the transmission. I've done all the repairs, maintenance, and mods myself.



Notable/unique mods

• On board hot water and shower
• Custom flooring
• Gutted interior
• 4 (or is it 5 now?) circuit breaker/fuse panels
• Solar panel under rack slide
• Double din radio mod w/ wakeboard tower style speakers

Major Work

• Engine rebuild
  • top hat flanged liners
  • Kent 180 camshaft
• Transfer case rebuild (in progress)
  • 1.41 High gear
  • Ashcroft HD Cross Pin
  • CDL

Exterior Mods

• 03/04 headlight conversion
• Roof rack mounted reverse lights
• Dual front spotties
• Front Runner slimline 2 roof rack
  • Removed a front slat to maintain an unobstructed sun roof
• Front Runner 40" LED Bar

Interior Mods

• Gutted all plastic trim including headliner, pillars, door panels, cargo bins, seat panels
• Gutted AC system including condenser, drier, pipes, compressor
• Removed 2 of the rear seats
• Custom flooring made of 1/2" black King starboard
  • Plentiful recessed l-track throughout
• Upper attic/shelf
• Window guards on both rear doors, cargo windows, and rear door
• Auber gauges to monitor voltage, water temp, oil temp, and oil pressure
  • Wired to a relay activated buzzer alarm. With disabling toggle switch

Nav/Audio

• Custom double DIN dash conversion
  • Pioneer 2330 NEX w/ micro bypass and steering wheel controls
  • Pioneer 5 channel amp
  • Infinity Reference front component speakers in custom made pvc door panel
  • "wakeboard tower" speaker bar mounted in rear roof to preserve floor space
    • Dual Polk Audio 8" subs
    • Pair of 6.5" speakers

• Front/rear cameras
• iPad Mini for GPS/nav using Gaia Maps (on ram mount)
• Garmin Inreach Explorer paired to iPad (on ram mount)
• iPhone 7 on ram mount

Cooling

• Replaced everything. Hoses, stat, water pump, viscous clutch, radiator
• OEM 180 grey thermostat

Offroad Mods

• Terrafirma beadlock 16x7 wheels
• BF Goodrich AT K02 235/85r16 tires (32" skinny)
• Extended stainless steel brake lines
• Onboard Air System. Dual viair 400c compressors. 2 gal tank. Custom panel on rear lower quarterpanel for dual needle air gauge, regulator, and push-to-connect fittings on both sides of truck
  • Water trap for each compressor
• Custom DIY breather extensions for transfer case, transmission, and both diffs. Parts sourced from McMaster-carr
• Mantec Snorkel
• Bushcables
• Smittybuilt synthetic winch
• Hi-lift jack w/ lift-mate and offroad-base
• Larsen CB and 2/70 antennas mounted to roof rack
• Cobra 75WXST remote CB radio
  • Handset mounted using a ram mount
  • External speaker in upper driver side roof area

Camping Mods

• On board hot water and shower system
  • Heat exchanger plumbed into the heater hose connection
  • Shurflo water pump
  • Shower arm attachment for roof rack
  • Honeywell thermostatic mixing valve and garden hose spigot / quick disconnect fitting
  • 12 gallon front runner roof rack water tank
  • Couple of custom made quick connect hose sprayers for dish washing, etc
• Dual 20L roof rack mounted jerry cans
• Dometic 65L fridge/freezer on slides and a custom made cubby box to fit 2 Cub Packs

Storage

• Rigid molle panels added to all 4 doors
• Dozens of molle pouches throughout
• Pelican Case w/ lid organizer
• Aluminum 42L case
• 6x cub packs fixed to floor using stratchits
• Cut out in both rear doors for longer tool storage (wrenches, hammers, etc)

Protection

• Front steel Terrafirma low profile winch bumper
• Rear steel Greg Davis bumper
• TF rock sliders
• TF aluminum gas tank skid plate
• TF front and rear diff guards

Steering & Suspension

• New steering box
• TF HD steering rods
• TF Adjustable panhard rod
• TF 3 degree castor corrected front radius arms
• TF Shock towers
• TF front upper dislocation cones and steel stud ring plate
• TF front lower spring retainers
• TF 3" all-terrain shocks
• SlickRockFab front sway bar disconnects
• New power steering components: pump, lines, hoses, reservoir, pulley

Maintenance

• All fluids have been changed
• Transmission filter replaced
• Brake calipers, pads, and rotors replaced

Electrical

• Dual battery
  • Odyssey Group 34's
  • ColumbiaOverland dual battery tray
  • Blue Sea ML-ACR 7622. Starter battery completed isolated from all other electronics
• Fuse panels
  • Engine bay
    • Blue Sea 6 circuit constant power
    • 8 circuit (4 switched, 4 constant)
    • 5-bank relay panel
  • Under steering wheel column
    • Blue sea 12 circuit panel. 6 constant, 6 switched
    • 80 amp solenoid
    • Busses for ground, switched power, and dash dimmer
  • Under passenger seat
    • Blue Sea SafetyHub 150 serves as a primary distribution point for all other interior fuse panels (single 2/0 gauge cable from battery to this panel)
      • Xantrex 600W inverter
      • Rear cargo circuit breaker
      • Steering column fuse panel
      • Audio amplifier
  • Rear cargo area
    • Blue Sea 360 custom circuit breaker panel
      • Blue Sea 1830 battery monitor
      • Morningstar Remote Meter
      • 4 circuit switch panel
      • 8 circuit breaker panel
      • USB, cig sockets, and Anderson power pole connections
      • Master shut-off switch
      • Xantrex remote monitor/switch
      • Shore power socket
        • Hooked up to xantrex inverter to automatically transfer loads using the relay
        • CTEK 25 amp battery charger
    • 4x anderson power pole outlets for solar panel hookups (upper rear pillar)
    • 5-bank relay panel
• Custom 200W under-rack solar panel slide out system
  • Doubles as an awning
  • MorningStar Sunsaver MPPT 15 amp controller

 

[Jeff Blake]

My next project is rebuilding the transfer case. Primarily for the CDL, but the rig is also a dog to get up hills (bounces between 2nd/3rd, can't go above 55 in 3rd), so I am going to rebuild it with 1.41 high range gears, along with a HD cross pin (stock design is prone to breakage during wheel spin).
Reason for regearing the tcase instead of the diffs: I don't particularly want to regear the diffs at this time. I'm going to run my stock axles and tires until the tires wear out, and then consider an increase in size to 34", and lockers. In doing so, it works out well to have the transfer case running 1.41 and doing a slight r&p regear for the increase from 32 to 34" tires.
1.41 is also the absolute perfect gearing for 32" tires.

I picked up an '04 transfer case and tore it down. Next step is to inspect the components for tolerance, clean the parts, and begin the rebuild. The annoying part of the process is setting the preload on the input gear and differential. It requires testing different shims, and to do so involves tearing it down and putting it back together again.

 

[KarrbonFiber]

Looks great. I've always loved the look of the Discovery II.

 

[khorsa]

Great looking truck, I've always liked them. I just don't want to mess with all the problems I read about them having lol.

 

[Jeff Blake]

Thanks. Discovery 2's get a bad rap for sure. But if you're willing to work on your own rig, I think they're a perfect option. Cheap, easy to work on, plentiful parts, and all issues and fixes are thoroughly documented.

 

[diabetiktaco]

Always get excited to see a disco. Nice truck

 

[AG Sheep]

I really dig these! Definitely on my list of realistic vehicles to own one day. Tearing down the transfer kind of sounds like tearing down a diff in the regards of utilizing shims and what not.

 

[CagedLife]

Amazing mods and lovely rig too. Following thread for inspiration. Cheers.

 

[ericmcduffie]

I am interested in Blue Sea ML-ACR and others for dual battery system. Did you wire the cable straightly from alternator to battery ?

 

[CatPowerDude]

great looking rig, enjoied reading your tasteful mod list

 

[Stoked]

Impressive work!

 

[JimG92]

Really smart vehicle with interesting build list - love it!

 

[jerdog53]

I do like a Disco!

 

[soarvet]

Nice work!

 

[WildernessDOC]

Wow this is an amazing build. I have been rebuilding a 2000 Discovery for the last year during COVId. I haven’t finished yet but my list is becoming almost as exhaustive as yours. I’d love to pick your brain sometime about your ride.

doc

 

[loper]

Awesome build. Lots of work there.

 

[Bullhab]

A bit late to the party here... but here she is. I've tried to list out all the mods I could remember below.

Photo album: Rover

View attachment 37739
View attachment 37740

2002 Discovery 2.

Purchased @ 106k miles. Currently 108k on the clock. Everything has been redone, more or less, except for the transmission. I've done all the repairs, maintenance, and mods myself.



Notable/unique mods

• On board hot water and shower
• Custom flooring
• Gutted interior
• 4 (or is it 5 now?) circuit breaker/fuse panels
• Solar panel under rack slide
• Double din radio mod w/ wakeboard tower style speakers

Major Work

• Engine rebuild
  • top hat flanged liners
  • Kent 180 camshaft
• Transfer case rebuild (in progress)
  • 1.41 High gear
  • Ashcroft HD Cross Pin
  • CDL

Exterior Mods

• 03/04 headlight conversion
• Roof rack mounted reverse lights
• Dual front spotties
• Front Runner slimline 2 roof rack
  • Removed a front slat to maintain an unobstructed sun roof
• Front Runner 40" LED Bar

Interior Mods

• Gutted all plastic trim including headliner, pillars, door panels, cargo bins, seat panels
• Gutted AC system including condenser, drier, pipes, compressor
• Removed 2 of the rear seats
• Custom flooring made of 1/2" black King starboard
  • Plentiful recessed l-track throughout
• Upper attic/shelf
• Window guards on both rear doors, cargo windows, and rear door
• Auber gauges to monitor voltage, water temp, oil temp, and oil pressure
  • Wired to a relay activated buzzer alarm. With disabling toggle switch

Nav/Audio

• Custom double DIN dash conversion
  • Pioneer 2330 NEX w/ micro bypass and steering wheel controls
  • Pioneer 5 channel amp
  • Infinity Reference front component speakers in custom made pvc door panel
  • "wakeboard tower" speaker bar mounted in rear roof to preserve floor space
    • Dual Polk Audio 8" subs
    • Pair of 6.5" speakers

• Front/rear cameras
• iPad Mini for GPS/nav using Gaia Maps (on ram mount)
• Garmin Inreach Explorer paired to iPad (on ram mount)
• iPhone 7 on ram mount

Cooling

• Replaced everything. Hoses, stat, water pump, viscous clutch, radiator
• OEM 180 grey thermostat

Offroad Mods

• Terrafirma beadlock 16x7 wheels
• BF Goodrich AT K02 235/85r16 tires (32" skinny)
• Extended stainless steel brake lines
• Onboard Air System. Dual viair 400c compressors. 2 gal tank. Custom panel on rear lower quarterpanel for dual needle air gauge, regulator, and push-to-connect fittings on both sides of truck
  • Water trap for each compressor
• Custom DIY breather extensions for transfer case, transmission, and both diffs. Parts sourced from McMaster-carr
• Mantec Snorkel
• Bushcables
• Smittybuilt synthetic winch
• Hi-lift jack w/ lift-mate and offroad-base
• Larsen CB and 2/70 antennas mounted to roof rack
• Cobra 75WXST remote CB radio
  • Handset mounted using a ram mount
  • External speaker in upper driver side roof area

Camping Mods

• On board hot water and shower system
  • Heat exchanger plumbed into the heater hose connection
  • Shurflo water pump
  • Shower arm attachment for roof rack
  • Honeywell thermostatic mixing valve and garden hose spigot / quick disconnect fitting
  • 12 gallon front runner roof rack water tank
  • Couple of custom made quick connect hose sprayers for dish washing, etc
• Dual 20L roof rack mounted jerry cans
• Dometic 65L fridge/freezer on slides and a custom made cubby box to fit 2 Cub Packs

Storage

• Rigid molle panels added to all 4 doors
• Dozens of molle pouches throughout
• Pelican Case w/ lid organizer
• Aluminum 42L case
• 6x cub packs fixed to floor using stratchits
• Cut out in both rear doors for longer tool storage (wrenches, hammers, etc)

Protection

• Front steel Terrafirma low profile winch bumper
• Rear steel Greg Davis bumper
• TF rock sliders
• TF aluminum gas tank skid plate
• TF front and rear diff guards

Steering & Suspension

• New steering box
• TF HD steering rods
• TF Adjustable panhard rod
• TF 3 degree castor corrected front radius arms
• TF Shock towers
• TF front upper dislocation cones and steel stud ring plate
• TF front lower spring retainers
• TF 3" all-terrain shocks
• SlickRockFab front sway bar disconnects
• New power steering components: pump, lines, hoses, reservoir, pulley

Maintenance

• All fluids have been changed
• Transmission filter replaced
• Brake calipers, pads, and rotors replaced

Electrical

• Dual battery
  • Odyssey Group 34's
  • ColumbiaOverland dual battery tray
  • Blue Sea ML-ACR 7622. Starter battery completed isolated from all other electronics
• Fuse panels
  • Engine bay
    • Blue Sea 6 circuit constant power
    • 8 circuit (4 switched, 4 constant)
    • 5-bank relay panel
  • Under steering wheel column
    • Blue sea 12 circuit panel. 6 constant, 6 switched
    • 80 amp solenoid
    • Busses for ground, switched power, and dash dimmer
  • Under passenger seat
    • Blue Sea SafetyHub 150 serves as a primary distribution point for all other interior fuse panels (single 2/0 gauge cable from battery to this panel)
      • Xantrex 600W inverter
      • Rear cargo circuit breaker
      • Steering column fuse panel
      • Audio amplifier
  • Rear cargo area
    • Blue Sea 360 custom circuit breaker panel
      • Blue Sea 1830 battery monitor
      • Morningstar Remote Meter
      • 4 circuit switch panel
      • 8 circuit breaker panel
      • USB, cig sockets, and Anderson power pole connections
      • Master shut-off switch
      • Xantrex remote monitor/switch
      • Shore power socket
        • Hooked up to xantrex inverter to automatically transfer loads using the relay
        • CTEK 25 amp battery charger
    • 4x anderson power pole outlets for solar panel hookups (upper rear pillar)
    • 5-bank relay panel
• Custom 200W under-rack solar panel slide out system
  • Doubles as an awning
  • MorningStar Sunsaver MPPT 15 amp controller

Absolutely outstanding!! I have a mildly modified 04 Disco 2.