P38A Diesel Engine Change with Manual Transmission

Lukas018 · Jan 22, 2020

Hi all,

I am now looking to do an engine swap on my P38 diesel (current engine not worth cost for repairing), I am aware of RAVE procedure for engine removal, just asking around if anyone has done a swap with a Manual gearbox and do they have any tips please?

Is it better to remove the engine with gearbox intact and remove transfer box?

I look to change the clutch while I am at it if anyone has tips for that also?

Cheers,

Datatek · Jan 22, 2020

Check the clutch release arm and the roll pins. The transfer box is very heavy.

brianp38dse · Jan 22, 2020

As Data mentioned do the roll pins in the clutch arm mine are triple pined after the second failure, i would leave the gearbox in its a big heavy unit.

kds · Jan 22, 2020

Leave the box in, getting engine out is the easy bit, getting it back in on to the box and engine mounts is another matter I had to remove the mount from the engine on one side to get every thing to line up but I did do the job by my self no help.

Grrrrrr · Jan 22, 2020

You're swapping manual into auto? Don't bother.

If pins are snapping check bushes.

Lukas018 · Jan 28, 2020

Grrrrrr said:
You're swapping manual into auto? Don't bother.

If pins are snapping check bushes.

I'm not just engine change but wanted to change clutch at same time.

RangeRoller dt · Jan 28, 2020

It’s how post #1 reads to the eye.

So you have an R380? - leave the box in and when you pull the engine the clutch will be bolted on the flywheel with it

Lukas018 · Jan 28, 2020

RangeRoller dt said:
It’s how post #1 reads to the eye.

So you have an R380? - leave the box in and when you pull the engine the clutch will be bolted on the flywheel with it

Ok thanks yea R380 as quite rare to have manual gearbox just wanted to see if anyone has swapped an engine on a manual P38 before

kds · Jan 28, 2020

Just to note, on the manual leave the bell housing on the engine unbolt bell housing from the main gearbox its to do with it being a pull type clutch. and yes I did couple of years ago.

Grrrrrr · Jan 28, 2020

kds said:
Just to note, on the manual leave the bell housing on the engine unbolt bell housing from the main gearbox its to do with it being a pull type clutch. and yes I did couple of years ago.

The engine moves forward enough to get off the gearbox shaft?

Definitely check the clutch fork bushes in the bell housing. The bushes should be covered in Teflon and no brass showing.

kds · Jan 29, 2020

I probable took the rad out so made a bit more room, I knew there was a problem with clutch cross shaft ( it broke in half many years ago, somebody drill and fitted oversize pins (not me) so dont do that so we welded forks and shaft up solid ) thought it easier take lot out to feed clutch forks over thrust bearing when removing and refitting bell housing (on my tod doing this dont forget) could be why it was a swine to get back together!

Grrrrrr · Jan 29, 2020

kds said:
I probable took the rad out so made a bit more room, I knew there was a problem with clutch cross shaft ( it broke in half many years ago, somebody drill and fitted oversize pins (not me) so dont do that so we welded forks and shaft up solid ) thought it easier take lot out to feed clutch forks over thrust bearing when removing and refitting bell housing (on my tod doing this dont forget) could be why it was a swine to get back together!

I am pretty sure the reason pins shear is because the Teflon wears down and friction material gets in making it harder to move. The rubber dust cap wears too.

Lukas018 · Jan 29, 2020

Brill thanks for this, reading comments, I have removed all the rads, steering pumps etc so removing engine have better access.

So am I best to remove the engine with the bell housing bolted to the engine then I can do any clutch work off the car?

thanks,

RangeRoller dt · Jan 29, 2020

If you can squeeze it out like that yes.

Think some have used rivet shafts or something to reinforce the clutch pins where they are hollow??

Try and take a few pics when you pull it

Datatek · Jan 29, 2020

Unless I'm

Lukas018 said:
Brill thanks for this, reading comments, I have removed all the rads, steering pumps etc so removing engine have better access.

So am I best to remove the engine with the bell housing bolted to the engine then I can do any clutch work off the car?

thanks,

Unless I'm mistaken, the bell housing is bolted to the gearbox from the inside, it certainly is on the auto, so you either part the bell housing from the engine or pull the engine and gearbox out in one piece which would not be easy.

tomcat59alan · Jan 29, 2020

Datatek said:
Unless I'm

Unless I'm mistaken, the bell housing is bolted to the gearbox from the inside, it certainly is on the auto, so you either part the bell housing from the engine or pull the engine and gearbox out in one piece which would not be easy.

Don't think so on the manual but I can check tomorrow if nobody replies.

Datatek · Jan 29, 2020

tomcat59alan said:
Don't think so on the manual but I can check tomorrow if nobody replies.

All the gearbox/bell housing interfaces that I have seen have been internally bolted.

tomcat59alan · Jan 29, 2020

Datatek said:
Unless I'm

Unless I'm mistaken, the bell housing is bolted to the gearbox from the inside, it certainly is on the auto, so you either part the bell housing from the engine or pull the engine and gearbox out in one piece which would not be easy.

The bellhousing on the manual is in two pieces,one is bolted to the gearbox the other to the engine and they can be separated, couldn't wait until tomorrow to check my memory.

Handy having spares in the garage.

tomcat59alan · Jan 29, 2020

Datatek said:
All the gearbox/bell housing interfaces that I have seen have been internally bolted.

The half that bolts to the gearbox is internal bolted.I remember owning a Vauxhall Cresta and you could unbolt the gearbox from the bellhousing and remove a pressed steel plate from the bottom of the bellhousing to replace the clutch. The gearbox was tiny, 3 speed column change.

Datatek · Jan 29, 2020

tomcat59alan said:
The bellhousing on the manual is in two pieces,one is bolted to the gearbox the other to the engine and they can be separated, couldn't wait until tomorrow to check my memory. Handy having spares in the garage.

That's novel, never seen one like that

P38A Diesel Engine Change with Manual Transmission

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