Member Since: 21 Mar 2020
Location: Essex
Posts: 26
My First Land Rover - 06 D3 HSE Project
I've wanted a Discovery 3 since 2010 but could not justify the expensive on such a big car and being single.
I've looked after my current car for years and do all the work it needs myself.
In recent years I wanted a project, and was looking at taking on a full restoration of a Defender.
However in order to scratch the itch of having a project I decided to purchase a non-structurally damaged Discovery 3.
So in February I went ahead and purchased a Copart CAT-N 2006 Discovery 3 HSE with 144k on the clock. I waited for some considerable amount of time for the right one to pop up in terms of spec, amount of damage, MOT history, selling price and so on.
This one has 4 owners before me, good MOT history and relatively good milage.
My plan now, is to repair this as cheaply but yet most sensibly as possible...
Here it is at the farm:
I checked over the car mechanically before taking the dive in to repair it, the engine sounded sweetly and everything worked as it should. I noticed the centre support bearing rubber had deteriorated on the rear propshaft. A slight amount of judder from the gearbox upon driving around on a private lane at the farm.
As you can see from the photos, a far amount of exterior damage and airbag deployment. I had a look around eBay at breakers on the parts that I needed, of which I was luckily able to find all the exterior (bonnet, wing, 2 x doors, curtain airbags, headlight, grille) all from one breaker fairly close to me and at a ridiculously low price too.
Here's some bits:
And obviously the very much needed diagnostic tool:
As the two front seat air bags had deployed, I wasn't happy for the leather to be re-stitched up given it needs to be the correct grade of stitching to release an air bag, so I opted to purchase two back seats from breakers on eBay again.
Out came the headlining and blown airbags:
Seat at home ready a strip down:
Off with the old wing damaged wing (at the front) and on with the better condition one:
Fuel Cap Repair:
Wing Mirror Repair:
Gearbox Oil Flush (Thanks to the guide on here )
Managed to purchase a rear GKN propshaft for £55+£20 postage from a breaker on eBay...they really didn't know what they was listing up! The white sticker you can see on the propshaft gave the product details just about, which stated it was a GKN from Bearmach. Looked in good condition so went ahead with it.
Out with the old, in with the new-er...
The front two tyres needing replacing, and the rears being mix-matched I was undecided what to do. While exploring my options, I found another great buy through eBay, 4 x HSE Wheels with Avon AX7 tyres for £132.00 (Had only done Approx. 6000 miles.):
Airbags all in place with no errors and ECU reset to normal, pre-tensioners replaced, seat belts replaced, Fluids all checked, brakes, discs, arms, struts etc etc and all good. Insured, taxed and put on the road.
With approx 2,000 miles now done, it drives lovely with no engine issues. There is a slight amount of judder now showing if going up-hill (suspect gearbox/torque converter). I've got the opportunity to purchase a low milage (67K) gearbox, transfer box & torque converter for a reasonable price which I'm going ahead with. Will fit this myself
To do:
- Find & Fix Air Con Leak
- Replace front off-side wheel bearing
- Find out if Oil Pump has been changed to the newer pump, if not it will be replaced
- Replace Timing Belt & Aux Belt & Tensioners etc
- Replace transfer box, gearbox and torque converter
- Find and fix suspension leak (Rear slowly lowers if left over 4-7 days).
I was reluctant to post up however I know that I have found it interesting reading through peoples builds etc over the years of lurking around on this site while having a cuppa, and I'm sure there are other that do the same
Sean.
3rd Aug 2020 12:54 pm
Lee Trinder
Member Since: 12 Aug 2018
Location: Henley in arden
Posts: 516
Well done on all of that mate, great work. Look forward to more.
3rd Aug 2020 5:42 pm
nigethecat
Member Since: 11 Sep 2016
Location: Marnoch
Posts: 4252
Good job! Brave to take on such a project, plenty of advice available here, and even more opinions
Just remember though, if there’s no pictures it didn’t happen I want to see the sweets before I get into your windowless van... I'm not stupid!
Corris Grey D4 Commercial SE 2016
Zermatt Sliver 2007 D3 SE manual (gone)
Indus Silver D4 HSE 2015 (gone)
Bonatti Grey D3 HSE 2006 (gone)
White D3 S (LHD) 2007 (gone)
Firenze Red D4 HSE 2014 (gone)
Black RRS 3.6TDV8 2008 (gone)
Rusty Green Defender 110 1997 (gone)
Black FL2 HSE 2013 (gone)
3rd Aug 2020 6:12 pm
Oswiperus D3 Decade
Member Since: 02 Apr 2010
Location: Chelmsford, Essex
Posts: 1600
Well done, nice to see one saved as plenty are heading to the breakers yard.
P.S. Nice beast that FW60, just a tad larger than my 7810!Stu
2016 D4 Landmark current
2022 Defender D300 SE Gone
D4 2014 XS Commercial - Gone
D4 2016 hse lux montalcino red - Gone
D3 2005 se java black - current
D3 2005 base manual - gone
D2 1999 TD5 E white - current
3rd Aug 2020 7:30 pm
DrRobH
Member Since: 10 Oct 2015
Location: Hampshire
Posts: 927
Keep the updates and piccies coming Visitor from fullfatrr.com
RR Vogue SE 2011 4.4 TDV8
1974 Lightweight
4th Aug 2020 7:17 am
lynalldiscovery
Member Since: 22 Dec 2009
Location: Maidstone
Posts: 7274
Always worth changing the gearbox oil before the gearbox, search on here for Filos gearbox oil change thread.
4th Aug 2020 11:52 am
SPT
Member Since: 21 Mar 2020
Location: Essex
Posts: 26
Thanks Gents Thoroughly enjoyed the project so far!
Noticed it was down on performance recently, upon inspection found a split in the intercooler pipe here:
Replaced with new:
Also picked up a parcel shelf, and the chap also asked if I wanted a dog guard for free as he was going to scrap it otherwise. As it was on my list of things to get I couldn't say no! Came with fittings too:
Also found my air con leak...
Any idea what pipe part number this is? It runs from under the rear passenger side door up to the back of the car, possible over and around the rear diff? I know I could blank it, but I want to keep the rear air if I can. TIA!
8th Aug 2020 4:48 pm
lynalldiscovery
Member Since: 22 Dec 2009
Location: Maidstone
Posts: 7274
There are 4 sections of rear a/c pipe @ approx 100/150 quid each section.
One on inner sill is normal failure point, then one from rear end of sill to top of rear diff.
Both of mine failed a couple of inches up inside the foam insulation.
9th Aug 2020 4:41 am
SPT
Member Since: 21 Mar 2020
Location: Essex
Posts: 26
Little update as it's been some time since I posted...
There's been plenty done in the last few months.
I gave it a further DIY flush as per the guide here, which has cured the judder going up hill.
I've also replaced one of the rear air con pipes, was a b* but just about do-able.
Both pipes come connected as a pair held on with two brackets, to get the old out I just undone them from the bracket and manipulated them both out.
Then fitting the new I just manoeuvred them around the chassis etc one pipe at a time and reconnected the bracket that holds them both together.
Photo below shows the new, and held in the position in which it runs under the chassis to the last section.
Replaced both rear drop links as one popped and broke.
I also had a whine from the front when coming off the accelerator 50/60mph+ so I checked the front diff to find this:
Happy with the symptoms being from the front diff, I went ahead and replaced the front differential with a decent secondhand one from a Discovery 4 that had done 83K. I also fitted a decent secondhand front prop shaft.
Test drive, problem solved
Also fixed a squeal from the aux tensioner.
And I gave her a oil and oil filter change
I recently completed an almost 1,000 mile trip up and around Wales and it drove without an issue. Loved it!
It's now at the point where I just need to check the oil pump and belts however I'm now on a longgg and intense course for work and I won't have anytime to do this.
I've also decided, having dipped my feet into working on a D3 and having loved driving the D3 that much that I now want to invest into a D4 with a view of keeping it long term.
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