Engine n gearbox change.

I have me another 200 tdi engine and lt 77 gearbox to put in my disco. I have been searching for answers all afternoon and got me a load of info but I could still do with some more info.

Can I remove the engine and gearbox together (using a decent crane), or do they need to be split..?

What parts would it be a good idea to replace while doing the job..? I will get a new clutch kit, but is there anything else..?

I think I now have all the basic info for doing the job, but any advice would be welcome

Oil seals and core plugs on the engine, timing belt. A hd clutch fork oil in box and tbox

Lyndon said:

Oil seals and core plugs on the engine, timing belt. A hd clutch fork oil in box and tbox

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Not heard of core plugs before n I see they are important to change, but where do they go..?

JonnyP said:

Not heard of core plugs before n I see they are important to change, but where do they go..?

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Round metal plugs that close up the holes in thewater galleries in block and head

The one on the back of the engine is most important as once it is in you can't get to it!!

Probably a good idea to de-grease and steam it too while it'son the floor as it'll make leaks easier to locate later on.

Might be an idea to change the Tbox output seals too as much easier when you can stand over then as opposed to laying under them.

Half wish I never asked now lol.. The engine I am putting in is out of another car and I was not intending to open it up..

Can I remove the engine and gearbox together (using a decent crane)..?

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Id say no. Not without a welder anyway

Finally getting onto this job soon..
Just ordered up a quality clutch kit, hd release fork, crankshaft oil seal and a timing belt kit including both pulleys.
I need to get me a clutch aligning tool, can anyone tell me if this will do the job, or do I need a better one..? CLUTCH MATE UNI CLUTCH ALIGNING TOOL STK.NO.52329 | eBay

I was told not to touch the core plugs unless they are leaking, so I don't know what to do about them..?
I am borrowing a crane off a mate and I still need to get all the fluids..

Anything else I might need..?

you can do the clutch by eye, or if the other lt77 is scrap, then cut the input shaft off and use that.

I use one of these and never have a problem with any of the clutches I've fitted.

1x Clutch Alignment Tool 4 piece multi-fit clutch mandrel Hand & Power Tools | eBay

Might be worth changing the clutch slave cylinder while ya doing everything else.. They is cheap as chips..

trax said:

you can do the clutch by eye, or if the other lt77 is scrap, then cut the input shaft off and use that.

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Old one is not scrap, I might try n recondition it. Good to know I can do it by eye though, I have only ever done one clutch before n that was a mk 11 cortina and I didnt know anything about aligning tools n it was a bitch to do..

Pikey said:

I use one of these and never have a problem with any of the clutches I've fitted.

1x Clutch Alignment Tool 4 piece multi-fit clutch mandrel Hand & Power Tools | eBay

Might be worth changing the clutch slave cylinder while ya doing everything else.. They is cheap as chips..

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Cheers Pikey, will get a new slave n push rod. Did I read once that its good to tie on the end of the push rod..?

JonnyP said:

Old one is not scrap, I might try n recondition it. Good to know I can do it by eye though, I have only ever done one clutch before n that was a mk 11 cortina and I didnt know anything about aligning tools n it was a bitch to do..

Cheers Pikey, will get a new slave n push rod. Did I read once that its good to tie on the end of the push rod..?

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well, there's always umming and arring if you do it by eye. for the price, i'd just buy the tool

trax said:

well, there's always umming and arring if you do it by eye. for the price, i'd just buy the tool

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Tis already bought

Hello guys,

On the subject of changing clutch...
How do you remove the top bolt on the gearbox cos its a fecker to get to?

Cheers

THE BUDDAH said:

Hello guys,

On the subject of changing clutch...
How do you remove the top bolt on the gearbox cos its a fecker to get to?

Cheers

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lower gear box and t/box down so engine tilts enough to reach bolt

Cheers James, i'll try n remember that. Not in a rush to do that job though...lol