Fitting new engine to gearbox

I'm doing the 200tdi conversion by myself. I have managed to get out the V8, and am now trying to fit the 200tdi to the gearbox. I have got it to the stage where the studs are just touching the gearbox, infact one of them is only just in the stud hole by about 1mm. I'm pushing and shoving like mad but cant seem to get it any further.

I remember someone saying on here its near impossible for one person to fit an engine by themselves unless your very strong, I'm realising that is true! I am strong, but not bloody superman!

Do I simply need more muscle to do this? I'm pretty sure the clutch is alinged correctly. Also it is going in slightly twisted. If only I could just get one stud in, then I could put a nut on it to stop the bloody thing coming out everytime I let go of it.

Any advice on this would be much appreciated! For a start do I need someone to help me push the engine the last inch or so home? or is it possible to do it by yourself? Any tips? Much thanks in advance.

have you modified gear box from v8 to tdi ,it helps to turn crank over at same time with socket, gap around must be equall .gear box propped up so it cant move engine must be slung square

jamesmartin said:

have you modified gear box from v8 to tdi ,it helps to turn crank over at same time with socket, gap around must be equall .gear box propped up so it cant move engine must be slung square

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The gearbox is a standard LT77 and hasnt had any mods, as the V8 was fittied to it via an adapter plate, so it should match up. Maybe I should prop the gearbox up more then, and square it up a bit more. I have tried turning the crank at the same time, but it means I can get even less push on it by trying to do both.

Is it possible for a strongish person to do it by themselves? or do you think I need help?

try taking out some studs and use longer bits of threaded rod with nuts to stop it all flying arround as you line it up., to mate up its got to be near perfectly aligned.

Have you checked the size of the spigot bush in the flywheel that the gearbox input shaft sits in? And as said it must line up correctly, can't be twisted at all.

ricc said:

try taking out some studs and use longer bits of threaded rod with nuts to stop it all flying arround as you line it up., to mate up its got to be near perfectly aligned.

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Yeah, Maybe I should take out the bottom 3 and put them back after. Just hope I can get the bloody things out again. On some of the studs I've taken out in the past, I've put 3 lock nuts on them, but still the nuts turned rather than the stud. I'll see if I can also try and get hold of some M10 threaded rod then. It's annoying because I have loads of M8 in my garage laying around.

GRATCH said:

Have you checked the size of the spigot bush in the flywheel that the gearbox input shaft sits in? And as said it must line up correctly, can't be twisted at all.

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I did roughly check that. It does all look the same. I guess only time will tell. Jeez what a hassle! Just to add, the bush should be the same anyway shouldnt it? as it's a standard LT77 box, and a 200tdi going into it which as we know does fit. Only differance is it's a disco 200tdi, and not a defender one.

Take out the rubber engine mounts, drop the engine onto the chassis and seeif it slides together. Had to do this twice to get the engine to slide into the gearbox without a problem. It is also the only way to gain access to the top stud to put a nut on.

Its in at last!! Main prob was as someone said it HAS to go in perfectly aligned all around. if its slightly up at the bottom or top then forget it. Even then It took me and a friend with a big lump of 2x2 as a lever to get the bitch all the way home. My mate has put in many engines, and he said this was the worse one he has ever done, it's such a big heavy bitch! and as patman1200 said, you have to leave off the rubber mounts too.

I'm just in the process of trying to get to all the bell housing studs to do them up, done most, just a couple of more to do (a couple are near impossible to get too). Also I put the 3 missing studs on the bellhousing before I put the engine in. it would have been easier to put them in after I think.

But thats the worse part over, just got to plumb it all in now, and alter the rad mounts etc. At 52 I'm starting to show my age, I ache like hell this morning, I could hardly get out of bed this morning with trying to get this engine in the last 2 days. I'll go to the gym later to try and loosen up.

It's a great feeling to have it in though, didn't think it would ever go, I was beginning to think all sorts, like is the clutch aligned properly, is it the wrong size spigot bush etc. Also it lined up perfectly with the engine mounts, which I did have some doubts being as I took out a V8 which is for sale by the way.

Anyway thanks to all for the good advice you all gave me.:5bcheers2:

I was planning to put my new engine and box in as one unit when I get that far you have just confirmed its the right plan for me

fett said:

I was planning to put my new engine and box in as one unit when I get that far you have just confirmed its the right plan for me

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Yes, it's got to be easier! Although you will prob still need some help doing that. It's guiding it in while trying to line everything up in position thats the problem. It's even easier when your doing a ground up resto, then you can put the engine/box on the chassis, and build the bodywork up around it. If I'd had the money, I would have put a galvanised chassis on for the hell of it, (even though it doesnt need it yet) and done it that way.

its all time and money mate. just gotta do the best you can with whats available to you