Lt77 Slave Cylinder Fitting

Hi just changed the clutch on a 300tdi and am getting ready to fit the engine into my 110 with a lt77 box installed. Have done the release bearing and arm and fitted a new lt77 slave cylinder, what i found was that when fitting, the rubber dust cover won't go through the hole so i have to put it on the release arm pin then try to fit back onto the cylinder once poked through, well thats impossible..am i missing something here? its hot and stupidity is more than possible but i don't get this at all, my land rover 110 1985 came without an engine and there was no slave attached to the gearbox so i'm missing reference points and haynes hasn't helped.
Any help would be gratefully received
thanks in advance

lubricate the rubber gaiter and carefully twist cylinder home

ok i feel a bit better now i had resorted to copper slip on it and it has gone home but feels like its trapped although the pin and arm are travelling ok , has pulled up tight though. Thanks for the advice as ever.

No harm in asking when you need a reference

correct me if im wrong but it's essential to use the red rubber grease......... normal petroleum greases will quickly east the rubber gaiter ?

windy81 said:

correct me if im wrong but it's essential to use the red rubber grease......... normal petroleum greases will quickly east the rubber gaiter ?

Click to expand...

I was thinking i might pull it again tonight and try to get it in with fairy liquid? it seems incredibly tight and i want it right before i mate them up as i suspect it would be a bugger to get at with the 300 sitting so close to the lt77.

I had the same problem when I replaced the slave cylinder on my 300tdi/LT77 combination. It is a right tw@ of a job when the engine is in.
As an aside, If you are using the 300tdi flywheel housing you need to grind the passenger side engine mount brace to avoid the slave cylinder. ( The bits that the earlier housings don't have.)

To get back to your problem, I found that the ridge inside the rubber boot is thicker on some pattern parts, which prevents fitting. I bu88ered about for ages trying to fit the slave cylinder, until I trimmed the ridge with a new stanley knife blade and then all fitted without any fuss.

Rougharse Racing said:

I had the same problem when I replaced the slave cylinder on my 300tdi/LT77 combination. It is a right tw@ of a job when the engine is in.
As an aside, If you are using the 300tdi flywheel housing you need to grind the passenger side engine mount brace to avoid the slave cylinder. ( The bits that the earlier housings don't have.)

To get back to your problem, I found that the ridge inside the rubber boot is thicker on some pattern parts, which prevents fitting. I bu88ered about for ages trying to fit the slave cylinder, until I trimmed the ridge with a new stanley knife blade and then all fitted without any fuss.

Click to expand...

Thanks for that advise i have ground back that bit and lined it all up whilst it was off, i am going to take it off again and get it so it fits properly incase i have to do it in the future as i can see it leaving the gaiter in the case if i did it with it joined up in the future Thanks again