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300TDi Swap Over Help

Discussion in '300 TDi' started by Fishbones78, Jun 14, 2018 at 3:36 PM.

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  1. Fishbones78

    Fishbones78 Member

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    Hello all,
    So for the past 2 weeks my 90 has been off of the road. Cruising the M1 before a big bang and a good constant knock. Upon inspection it has eaten the number 1 shell. I have no idea how, but the two nuts securing the big end spun loose. The threads are not stripped. Crankshaft severely scored. New engine as time is against me. Possibly rebuild this in my spare time so I can have myself a mint engine.

    I have no idea how this has happened.

    Anyway. Picking up a 300TDi Disco Sunday. My 90 is actually a 300Tdi from a 19J conversion. Late F reg. I've tried having a browse around and the seen little advice besides specific parts of the engine in/out process. I am happy to literally tear the engine out of the Disco as it is the common rotten MoT failure type :p 96K on the clock so mileage is fairly low. More importantly though, is not damaging my 90, and doing the job properly.

    Is there anything specific I need to watch for? As far as I am concerned:
    Disconnect and drain everything.
    Undo bellhousing bolts and support gearbox (LT77)
    Undo engine mounts and lift. Plan on removing front grille for some clearance.

    Never ripped out an engine before. Any pointers appreciated. Would like this done in a few days as I really could do with the car back, insurance alone is costing me £205 a month!

    Many Thanks
     
  2. callisr

    callisr Well-Known Member

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    That’s pretty much it! Just remember that the engine sits quite close to the bulkhead so be mindful of that as you lift it clear of the mounts. Other that that, one out, one in. You don’t need to be too precious about the disco (I just cut off everything in the way (including the transmission tunnel) to make the extraction as easy as possible)
    I’m sure you will be fine with this but just go steady, concentrate on one thing at a time and enjoy it. A few days for a straight swap should be easily doable! Certainly can’t think of owt that’ll bite you on the arse!!

    Let us know how you get on!

    Rich
     
  3. Kwakerman

    Kwakerman Well-Known Member

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    Worth chucking a new clutch in while the engine is out, will save you time in the long run.
     
  4. Flossie

    Flossie Well-Known Member

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    Definitely take the front panel out.
    If your transmission tunnel and bulkhead panel will remove easily then do that too, makes bell housing/starter motor Access a doddle.
    Mine come out easily because I replaced all the screws and bolts/nuts with stainless steel, I can have those panels and the floor plates out in 20mins or so.
    If all the fixings for the above are rusted in then it's a pita to get some of them out and if time is an issue then don't bother.
    It just makes the job a pleasure cos the bell housing bolts are in full view, no struggling.
    Disconnect battery before doing anything!
     
  5. Fishbones78

    Fishbones78 Member

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    Will do. Thanks for the reassurance haha! I do plan on just cutting into the poor disco to get it done as quickly as possible, stealing the transfer box for the 90 too and selling the gearbox. Then I will take it to its death down the local scrappy :(
    Good shout. I will do this. I think I heard the forks fail a lot so will replace this too.
    Thanks
     
  6. Kwakerman

    Kwakerman Well-Known Member

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    Yea, if its a keeper just change everything that is inaccessable while you have the opportunity
     
  7. Fishbones78

    Fishbones78 Member

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    Okay, will give it a shot. My 90 has been molested a lot by its 14 previous owners (bought it from a friend so wasn't too in on the details when purchasing!) down to the fusebox and everything. I'm trying to revert everything back but it would not surprise me if half of the bolts are missing :')
     
  8. Kwakerman

    Kwakerman Well-Known Member

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    If you are scrapping it it may be worth pulling the rear half shafts and diff out to keep as spares?.
     
  9. Fishbones78

    Fishbones78 Member

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    Chassis isn't too bad and I've only out 200 miles on it! 100% a keeper as I owe 5 months wages for it!
     
  10. Fishbones78

    Fishbones78 Member

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    Are they the same? It has just had rear half shafts, but as you say, may as well keep them. Thanks
     
  11. Kwakerman

    Kwakerman Well-Known Member

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    Generally yes, there are 10 spline and 24 spline versions (24 are better) and there are a couple of types of input flange (which are cheap and easy to change) but things can get swapped around over the years so only a physical look can actually prove what you have
     
  12. Fishbones78

    Fishbones78 Member

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    I have quickly had the rear axle apart to change a leaky seal. I think (from vague memory) they are 10 spline. Already put new Terrafirma flanges on and I think they were the thicker type. Will give the Disco halfshafts etc a look.
    Thanks
     
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