200TDi Swap Concerns

Swapped from 2.5na to a Disco 200TDi and we're having some issues with the flywheel housing studs.

They all seem to line up just fine, but the engine nor transmission seem to be able to move together with enough thread on the studs to tighten things.

We're thinking this could be a problem with the clutch shaft not lining up or some such.

If we tighten the bottom nuts, would that ruin the clutch? I mean, the studs on the housing are lined up perfectly, but we are still seemingly catching on something. :doh:

Yep, sounds like your clutch isn't lining up properly. Don't force it - you'll knacker something.

Get a jack under the gearbox so you can raise and lower it. Also, a load-leveller on the engine hoist will help. I tried for hours to get mine to go in - eventually took it out as I was convinced I hadn't got the clutch centred properly. Everything looked fine so I tried it again and it plopped straight in! Get a socket on the end of the crankshaft and turn it very slightly too - it might be that the splines aren't lining up.

check for dowels to

It has to go in perfectly straight. If not it won't go. It took me about 5 times to get mine in. It's disheartening but even if you have some studs on and it won't go, you have to pull it back and start again. Try changing the angle of the engine until it goes in. Once you can get opposite nuts on a few turns you can start tightening them up to pull the gearbox onto the bell housing but make sure it stays perfectly in line at all times.

Ahhh, thanks for the help. I'll give it another go today.

Maybe the gearbox input shaft is a tight fit in the flywheel spigot bearing
I bought a new on the other day from bearmach 78p!


Lynall