From: "Ron Beckett" <hillman_at_bigpond.com>
Subject: Disco Firewall Cracks
Date: Wed, 31 Dec 1997 12:43:50 +1100

I've been hearing rumours recently of Discos with cracks appearing in their firewalls (bulkheads?) above the chassis body mounts on both sides of the firewall.

Apparently it is only appearing on pre-96 models but it may also be that they are too new for the problem to have appeared - yet. Perhaps Rover fixed the problem?

Is it true?
Is it occurring in countries other than Australia? Is the problem exacerbated by corrugated roads (pretty common in Australia).

Any comments from others on the list?

Regards,

Ron Beckett
Emu Plains, NSW, Australia

'86 Range Rover 4.6L auto (The Last Aquila) '71 Hillman Hunter Royal 660 1725cc manual '67 Hillman Gazelle 1725cc auto
'67 Hillman Gazelle 1725cc manual

check my home page at
http://www.users.bigpond.com/hillman for Hillman and Rover

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Date: Thu, 1 Jan 1998 08:43:34 +1100
From: Phillip Simpson <biochem_at_netcore.com.au> Subject: Disco Firewall cracks

In response to Ron's query re firewall cracks I can confirm that this is a fact and not just speculation or industry gossip.

I have a '95 TDi Disco woth 49000km on the clock. It has just returned from having the firewall cracks repaired. My vehicle runs on standard suspension but has been used for what it was designed for ie 4WD offroad use. At all times it is driven using the "TREAD LIGHTLY" approach and has certainly not been an off road racer.

In looking into this matter I found the following:

  1. I've seen the problem on Disco's from '93-96 construction.
  2. Problem is found on vehicles with standard and nonstandard suspension.
  3. Many owners are unaware of the problem in the early stages as they are

    difficult to see until they are quite advanced (unless you know what to look for).

  4. In advanced stages the crack become big enough to put 2-3 fingers through.
  5. My vehicle was repaired under Land Rover Australia supervision, which

    indicates to me some knowledge of the situation.

  6. Initial ,and regretably current official thinking, is indicating that the

    problem is caused/exasperbated by fitment of nonstandard suspension to the Disco. I find this hard to understand considering my own vehicle.

  7. I've heard of 3rd party service organisations who seem to service Disco's

    used for 4WD use and not just shopping trolleys, that a large majority of their customers vehicles have cracks in the firewall.

I am providing this response to Ron's query as I believe this is an important issue for all Disco owners. The firewall is part of the structual integrity of the vehicle and any cracks in this structure need attention. Now that my vehicle has been repaired it is my intention to keep using it for what I bought it for as I still believe it is one of the finest 4WD in the world.
I guess I have to admit I have Solihull fever.

Regards

Phillip Simpson

'95 TDi Disco
'87 Range Rover Hiline
'52 Series One + 2 others under restoration

From owner-cso-digest_at_playground.sun.com Sun Jan 4 07:00:51 1998

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Date: Sun, 04 Jan 1998 18:40:49 -0800
From: Phillip Simpson <biochem_at_netcore.com.au> Subject: Finding Disco Firewall cracks

The best way to find the cracks is to look underneath on the right hand side of the vehicle (facing forwards).
400 mm back from the front shock absorber there is a body/chassis mount on the outer edge of the chassis. This has a bottom plate 75mm going in towards the engine. From the inner edge of this runs upwards a 100mm plate that then connects onto another plate connected and running down the firewall. The cracks normally start as a fine line about 10-15mm long, running from across the top of thie firewall connecting plate.They are about 5-10mm above the top of the plate. In the beginning they are almost closed, but in extreme cases open right up as the firewall appears to collapse forward.

Sometimes it is easier to feel them with a fingernail. Todate I've seen most cracks on the drivers side (we drive on the left hand side) though usually they appear on both sides. The other side has a similar connection.

>From the top side this area is directly below the clutch fluid reservoir.

Hope this helps to identify the area. I would be interested to hear what you find.

Regards
Phillip