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M57 6 speed manual Defender 90

What Syncro Gearbox Parts Are You Using? : ZF GS6-37 to LT230 Adapter

I bought my 1992 Defender 90 TDI in August 2003, so after 20 years of reliable service from the 200 TDI and after replacing the chassis and bulkhead and many other parts in recent years, and much soul searching, I decided to go down the M57 route. It is my daily driver and also my tow vehicle, so heavy trailer work defined my specification. Although an auto option is excellent to drive, I wanted to keep everything else as traditional as possible. I was offered an M57 from a Range Rover L322, with the advantage that I knew the owner, mileage was a respectable 115K, and it has the ‘Landrover’ engine covers. However, an M57 from a manual BMW would have been a simpler and cheaper option.
My build spec is the M57 306D1 engine, 330D sump and DMF, Stage 1 mapped ECU, Clutchfix clutch kit, ZF GS6-37 gearbox from a BMW 520D, Syncro adapter kit for the LT230, Ashcroft 1.1:1 ratio gears and full rebuild of the transfer box, uprated alloy TD5 radiator, Allisport full width intercooler, Landrover TDCI throttle pedal and Wisemans Engineering stand-alone wiring harness. I prepped the engine and gearbox and accumulated all the necessary conversion parts over several months last winter, but had too many jobs to do requiring the Landy and trailer until August 2023, when I took it off the road for what turned out to be a month doing the conversion. This included me fabricating all the necessary mountings, supports. exhaust, Intercooler mods etc. and delays due to various uncharted events: Galvanising of fabricated items delayed by 1 week due to August bank holiday shutdown, INPA software installation issues, faulty throttle pedal, failed fuel pressure regulating valve seals, failed HP fuel pump seals. etc. The only work I had to outsource was some alloy welding to modify my original Allisport 200 TDI intercooler.
Now having driven it for a month, it is better than I expected. Smooth, slick gearbox, plenty of low down torque, and perfect ratios for towing. A joy to drive. Thanks to Shabs at Syncro Gearboxes for his assistance and suport.

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