Urgent assistance! Can't get my engine back in!

I've been trying all day to get my 300tdi back into my Defender, but I simply can't get the engine to line up correctly with the gear box! If the top is lined up, the bottom is around an inch out and the closest I can get with equal gaps around the bell housing is a good couple of CM out!

Does anyone have any suggestions/tips/ideas about why everything isn't lining up??

I'm certain that the clutch alignment is correct, but I can't think of anything else that would cause the engine not to simply slide into place?

This is now becoming quite urgent because I'm blocking 2 driveways and my neighbours are starting to lose patience

Help!!

can you get any of the bolts in so it will stay lined up even if there is a gap and then turn the gearbox or the crank whilst gently helping it home. if your on your own it will be a right pain.

how did you line the clutch up. by eye or by the kit. you only need to be a fraction out to cause problems.have you fitted a new clutch plate, if so are the number of splines the same as input shaft.just a couple of ideas but worth a look. also. if you can find a couple of longer bolts, place them opposite sides of engine and w2ind em in slowly a bit at a time. (i used threaded bar )


ron.

Rasher said:

can you get any of the bolts in so it will stay lined up even if there is a gap and then turn the gearbox or the crank whilst gently helping it home. if your on your own it will be a right pain.

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There are a couple of us working on it. We've tried turning the crank, but with no success

how does the spigot bush / bearing look or feel?
the 20mm you say it wont line up is around that depth.

Make sure its in gear when turning crank or input shaft will spin with the engine.
Only have to be a fraction out with clutch line up and it wont go in.

Thank all! Now sorted! Will report back later!

what was the problem and how did you solve it?

glad your sorted chris. be interested to know what the problem was.


ron.

Well... After almost 7 hours of fighting the engine, would you believe that I posted on LZ, then walked back over to the hoist with the intention of lifting the engine back out and the bloody thing slipped into place just enough to get some nuts/bolts in place! I then simply worked around the bell housing, gradually tightening everything.

It was a huge relief to finally get the engine in, but hugely frustrating considering that I didn't do anything different to what I had been doing all day! But the engine is now in and mostly reconnected, so I suppose alls well that ends well!

Thanks again for the advice!

Chris

Chr1s said:

Well... After almost 7 hours of fighting the engine, would you believe that I posted on LZ, then walked back over to the hoist with the intention of lifting the engine back out and the bloody thing slipped into place just enough to get some nuts/bolts in place! I then simply worked around the bell housing, gradually tightening everything.

It was a huge relief to finally get the engine in, but hugely frustrating considering that I didn't do anything different to what I had been doing all day! But the engine is now in and mostly reconnected, so I suppose alls well that ends well!

Thanks again for the advice!

Chris

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Just a cup of tea usually does it, glad it went in for you.

its amazing what effect LZ can have

:tea:

Years ago I spent the best part of a day trying to get the engine back in a series. I was using a scaffold tube tripod and having to move the vehicle rather than the engine. About 3 pm I gave up went for a cup of tea and rang a mate to help me after he finished work.
When he came round we had a cup of tea while I explained the problem. We went out to look at it, he leant against the tripod to have a look and it slipped straight in ! I wasn't impressed.
Another time helping another mate change gearbox in a series 3 we got it back in and all bell housing bolts done ready to put props on, reached to dashboard only to see the release bearing by the prop tool!
Went for a cup of tea the started again!

The Mad Hat Man said:

its amazing what effect LZ can have

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are you saying that peeps scared the engine into fitting?

We have powers you would not believe

The Mad Hat Man said:

We have powers you would not believe

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We have the technology