fitting a 200tdi

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chris07

chris07

Active Member
Posts
413
Location
musselburgh the honest toun
:confused: hi evrayone im trying to fit a 200tdi from a disco in to a 90 and am strugaling to get the engine to mate with the gearbox the last 10mm or so is there enayone local to me that could help in exchange for sum beer tokens ovcorce :D thanks chris


or if enayone has enay tips to help ad be very gratfule
 
av tapt the disco flywheel housing and checkt it was fiting the gear box b4 a re fited to the engine i also turnd the crank but still nufing av got it as square as a can get it but still it wont go it dusent help that am trying to do it all my self thanks for the replys guys
 
I swapped the bell housings and still couldn't get the engine to go in first time. In the end I took it out again as I was convinced I must have got the clutch off centre or something. But nope, it was all good. Tried it again and it plopped straight into position!

I know that's not a lot of use - but I think getting the angle right is critical, so get a jack under the gearbox and move that up and down a little too. You will get there in the end!
 
Persevere my friend. I had the same with mine, everything was correct but it just wouldn’t go in the last inch! My mate lent me a load level for the hoist, after I played with some different settings it popped straight in. Good luck, it’ll be worth it in the end.
 
have done a 200 disco and 300 disco in my fender

its defo a 2 man job tho

getting the engine in at the right angle is the key to getting it in
we took footwells and gearbox tunnel out so i could stand in and me mate controlled the engine hoist and with help from me and me crowbar it popped in
 
As some have seen, i've literally just put mine in, it wasn't sitting right to start with, you've got to align both gearbox and engine , if it's off slightly ( my engine was pointing upwards slightly ) it'll be a bastard.

If the housings are correct, it's just a case of perserving mate, it'll come to you in the end.

Yes 2 are better than one purely to have someone using the engine crane ( i got wifey to pump and release for me :D )
 
Make sure that the gearbox is in gear and diff lock also helps.
Then you can wriggle the shaft as it goes in by turning the handbrake drum back and too slightly as you push. :)
 
Same story for me as Squiddy - I spent about 2 hours too-ing and fro-ing and adjusting and wiggling and swearing and shouting at it... went in for a cup of tea and quick read of LZ to calm down. When I went out to try again, it went on within 5 minutes. Such a nice feeling when it closes up and you can get that first nut on :D
 
thanks for all you kind words guys all have a nuther go tomoro a do have one good tip to get the engine near the box take out the botom two studs and fit sum m10 rod one at 100mm and one at 125 mm that makes it so mutch easier to get it in line
 
chris07 said:
thanks for all you kind words guys all have a nuther go tomoro a do have one good tip to get the engine near the box take out the botom two studs and fit sum m10 rod one at 100mm and one at 125 mm that makes it so mutch easier to get it in line
Click to expand...
Dont forget to put it in gear or the gearbox shaft will be difficult to locate in the clutch as it will turn with the engine as you try you locate it.:)
 
I do loads of clutches on these. Best way for me is a piece of 19mm ply on a trolley jack under the gearbox bellhousing and engine. Jack up until gap is even all around and they slide perfectly. This flat plate makes them line up perfectly for the last 20 mm or so. the bottom edges sit on the ply. Works every time and I did my 2.5na gearbox swap last weekend on my own in the drive in 8 hours. Split gearbox from transfer box for both removal and install. Just posted about fixing my old box!:)
 
chris07 said:
thanks for all you kind words guys all have a nuther go tomoro a do have one good tip to get the engine near the box take out the botom two studs and fit sum m10 rod one at 100mm and one at 125 mm that makes it so mutch easier to get it in line
Click to expand...
Is it in yet? :)
 
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