Diesel to Gearbox fitting problem

O.K., finally got around to fitting a Peugeot XD2 diesel engine into a 109
SIII (originally fitted with a 2.25 LR diesel).
The engine support brackets and the engine to gearbox adapter (or flywheel
housing assy) have been sized such that the position of the gearbox primary
pinion into the bronze flywheel bearing is the same for Peugeot engine to
box in reference to LR engine to box.
Now here's the problem. Both the original LR clutch as well as the Peugeot
type clutch are of the type but to release the Peugeot clutch the clutch
release bearing has to be in a position that is 12mm more towards the engine
in reference to the original LR clutch.

Question : How can this problem be solved?
- a 12mm spacer between the diaphragm "tongues" and the release bearing?
- a proportionally longer slave cylinder pushrod?
- other options?
- don't care? (there might be enough possible travel from the slave cylinder
piston)
B.t.w., it is the later type gearbox with the clutch cylinder mounted
horizontal on the lefthand side on the bell housing.

I hope the description makes sense, t.i.a.,

Jan.

Hi Jan, I've been advised that using the engine makers clutch (Daihatsu in
my case) that there isn't enough travel in the LR clutch mechanism. So it
was advised to have the flywheel drilled and tapped to suit the LR clutch
pressure plate. HTH.

Roy.

"J.Koning" <[email protected]> wrote in message
news:[email protected]...
> O.K., finally got around to fitting a Peugeot XD2 diesel engine into a 109
> SIII (originally fitted with a 2.25 LR diesel).
> The engine support brackets and the engine to gearbox adapter (or flywheel
> housing assy) have been sized such that the position of the gearbox
> primary
> pinion into the bronze flywheel bearing is the same for Peugeot engine to
> box in reference to LR engine to box.
> Now here's the problem. Both the original LR clutch as well as the Peugeot
> type clutch are of the type but to release the Peugeot clutch the clutch
> release bearing has to be in a position that is 12mm more towards the
> engine
> in reference to the original LR clutch.
>
> Question : How can this problem be solved?
> - a 12mm spacer between the diaphragm "tongues" and the release bearing?
> - a proportionally longer slave cylinder pushrod?
> - other options?
> - don't care? (there might be enough possible travel from the slave
> cylinder
> piston)
> B.t.w., it is the later type gearbox with the clutch cylinder mounted
> horizontal on the lefthand side on the bell housing.
>
> I hope the description makes sense, t.i.a.,
>
> Jan.
>
>

Hi Roy, your solution did'nt strike my mind before. So, thanks for the
spark. It certainly is an option but a rather drastic one. For example, the
Peugeot clutch is smaller in diameter than the LR one. The Peugeot engine
flywheel has a rather odd shape, i.e. it has circumferential lip around the
clutch plate face area that would have to be machined off to allow for the
larger LR clutch plate and clutch pressure plate. Next to that, drilling and
tapping for bolting down the the LR pressure plate would be neccessary.
Also, if machined off, I don't have any idea how the (somewhat) reduced
flywheel mass/inertia would affect the engine characteristics.
As said, certainly it's an option and doable but right now I would prefer to
go for an easier solution.
Any other ideas?

Rgds,
Jan.


"LR90" <[email protected]> wrote in message
news:[email protected]...
> Hi Jan, I've been advised that using the engine makers clutch (Daihatsu in
> my case) that there isn't enough travel in the LR clutch mechanism. So it
> was advised to have the flywheel drilled and tapped to suit the LR clutch
> pressure plate. HTH.
>
> Roy.
>
> "J.Koning" <[email protected]> wrote in message
> news:[email protected]...
> > O.K., finally got around to fitting a Peugeot XD2 diesel engine into a
109
> > SIII (originally fitted with a 2.25 LR diesel).
> > The engine support brackets and the engine to gearbox adapter (or
flywheel
> > housing assy) have been sized such that the position of the gearbox
> > primary
> > pinion into the bronze flywheel bearing is the same for Peugeot engine
to
> > box in reference to LR engine to box.
> > Now here's the problem. Both the original LR clutch as well as the
Peugeot
> > type clutch are of the type but to release the Peugeot clutch the
clutch
> > release bearing has to be in a position that is 12mm more towards the
> > engine
> > in reference to the original LR clutch.
> >
> > Question : How can this problem be solved?
> > - a 12mm spacer between the diaphragm "tongues" and the release bearing?
> > - a proportionally longer slave cylinder pushrod?
> > - other options?
> > - don't care? (there might be enough possible travel from the slave
> > cylinder
> > piston)
> > B.t.w., it is the later type gearbox with the clutch cylinder mounted
> > horizontal on the lefthand side on the bell housing.
> >
> > I hope the description makes sense, t.i.a.,
> >
> > Jan.
> >
> >
>
>

> Question : How can this problem be solved?
> - a 12mm spacer between the diaphragm "tongues" and the release bearing?
> - a proportionally longer slave cylinder pushrod?
> - other options?
> - don't care? (there might be enough possible travel from the slave
cylinder
> piston)
> B.t.w., it is the later type gearbox with the clutch cylinder mounted
> horizontal on the lefthand side on the bell housing.


I'd make a 12mm spacer to fit onto the face of the release bearing and I'd
tack weld it on. Lots of juce to get good penetration of the weld and then
cool it fairly quickly so the heat didn't get too much to the grease. Doing
a short 'tack', cooling it, then another short 'tack'. Only need, say, four
equaly spaced to hold it on.
I fited a Hillman Imp engine to a Ford type 9 gearbox like this... don't
ask! LOL
Toby

TVS wrote:

> I'd make a 12mm spacer to fit onto the face of the release bearing and I'd
> tack weld it on. Lots of juce to get good penetration of the weld and then
> cool it fairly quickly so the heat didn't get too much to the grease. Doing
> a short 'tack', cooling it, then another short 'tack'. Only need, say, four
> equaly spaced to hold it on.

I've done the same in the past, but I find it easier to wander down to
my local brake and clutch supplier with the existing bearing and see if
he can match it up to a longer one - he normally comes up with something
to work.


--
EMB

"EMB" <[email protected]> wrote in message
news:[email protected]...
> TVS wrote:
>
> > I'd make a 12mm spacer to fit onto the face of the release bearing and
I'd
> > tack weld it on. Lots of juce to get good penetration of the weld and
then
> > cool it fairly quickly so the heat didn't get too much to the grease.
Doing
> > a short 'tack', cooling it, then another short 'tack'. Only need, say,
four
> > equaly spaced to hold it on.
>
> I've done the same in the past, but I find it easier to wander down to
> my local brake and clutch supplier with the existing bearing and see if
> he can match it up to a longer one - he normally comes up with something
> to work.

"Sorry mate... we only sell complete kits and can't split them"
Humm... where is this counrty going? Toby