Bellhousing Bolts - 300Tdi - LT77 - 2.5NA Bellhousing (I think) - How????

Saint.V8 · Mar 1, 2017

In the process of removing my 300Tdi due to a leaking Core Plug.....

It is mated to the LT77 using what I believe is the 2.5NA or TD bellhousing, this means the engine sits quite a way back in the engine bay only a couple of inches from the bulkhead.

All engine connections are removed, I couldn't for love nor money get to or even undo the exhaust downpipe manifold bolts/nuts so I have remove the intake and undone the exhaust manifold from the head.

The top few Bellhousing bolts are really close to the transmission tunnel and bulkhead sides, (see photos).....

How is it best to begin to undo these and separate the engine and the box?

wammers · Mar 1, 2017

Usually you would do the job on a ramp, drop the rear of the box down and get at them with a socket maybe a wobbler and extensions.

zeaphod · Mar 1, 2017

Remove the transmission tunnel cover and undo them from inside.

Saint.V8 · Mar 1, 2017

Will update later with photos once we have put the daughter to bed, but in the end I took the rubber engine mounts out, too the alternator side engine mount bracket off (couldn't get the passenger one off as the lower bolt was nigh on impossible to get at!).

Then, lowered the engine so the Alternator was mere millimetres from the chassis rail and you could just about get to the top 4 bolts......I thought that would be the hard part.....Oh no....

Next were the two bolts tucked up by the starter motor that needed a pair of UJ adaptors and extension bars to get a socket on to.....not looking forward to replacing those....

Anywho, in the end, it took me as long to undo the bellhousing nuts as it did to prep the engine for lifting out!!

Photos to follow!

owas · Mar 1, 2017

Easiest way wouldve been to just remove the tunnel.

It took me 2 UJs to just tighten up my exhaust down pipe nuts on my conversion so i can imagine ill too not be able to get mine back off, i used a 45 bend and completly forgot i still needed to get to the nuts

zeaphod · Mar 2, 2017

Take the floors and transmission tunnel off, and remove the nearside wing - then you can get at everything easily.

Shanec · Mar 2, 2017

Your fans already off but if the vehicle were operational the fastest way I have found is fan off, rubber mounts off, chassis member out, tilt engine back whilst supporting underneath, engine crane in through seatbox area.

Marmaduke · Mar 2, 2017

Shanec said:
Your fans already off but if the vehicle were operational the fastest way I have found is fan off, rubber mounts off, chassis member out, tilt engine back whilst supporting underneath, engine crane in through seatbox area.

How does that get an engine out?

Shanec · Mar 2, 2017

By separating the box from the engine. Or is he taking the boxes with the engine?
One thing I did forget - propshafts

Oldseadog · Mar 2, 2017

Shanec said:
Your fans already off but if the vehicle were operational the fastest way I have found is fan off, rubber mounts off, chassis member out, tilt engine back whilst supporting underneath, engine crane in through seatbox area.

And of course everyone has at least one spare engine crane in his back pocket!

Shanec · Mar 2, 2017

Also works works well with forklift with one fork through the door

Or jack.
or if you don't own a jack, a fence post and rope...

Saint.V8 · Mar 2, 2017

Just removing the engine....I will be posting some pics later with luck.

In the end I undid the rubber engine mounts, lifted the engine up, took out the rubbers, removed the N/S engine bracket, lowered engine as far as it would go and I managed to get a spanner on the 4 top bellhousing bolts with a bit of a reach....

Once they were off, lifted engine back up, supported the box on a Sealy 3 Tonne Yankee, undid the remainder - some were a right PITA tucked up under the tranny tunnel - then once undone, pulled the engine out, lowered gearbox onto a block of wood on the chassis cross member, jobs a good'un.

neilly · Mar 2, 2017

Saint.V8 said:
Just removing the engine....I will be posting some pics later with luck.

In the end I undid the rubber engine mounts, lifted the engine up, took out the rubbers, removed the N/S engine bracket, lowered engine as far as it would go and I managed to get a spanner on the 4 top bellhousing bolts with a bit of a reach....

Once they were off, lifted engine back up, supported the box on a Sealy 3 Tonne Yankee, undid the remainder - some were a right PITA tucked up under the tranny tunnel - then once undone, pulled the engine out, lowered gearbox onto a block of wood on the chassis cross member, jobs a good'un.

Sounds fun...........Now fix it and put it all back together.................LOL.

Cheers

Marmaduke · Mar 2, 2017

Am I missing something? Everyone is telling you to take the transmission tunnel out

Wait til you try and get it mated up

Saint.V8 · Mar 2, 2017

Marmaduke said:
Am I missing something? Everyone is telling you to take the transmission tunnel out

Wait til you try and get it mated up

Nope not missing anything......The tunnel out option was mentioned after I had already managed to get to the top bolts!!

As you say, putting it back is a whole new game of Cricket!!

IamRobbie · Mar 3, 2017

Defo need tunnel out makes it alot easier

Flossie · Mar 3, 2017

Yep, tunnel out, all the bolts are easy then.

owas · Mar 3, 2017

Flossie said:
Yep, tunnel out, all the bolts are easy then.

Also makes grinding one off when it rounds easier too

Saint.V8 · Mar 3, 2017

I have taken the gear stick tunnel off and the tunnel panel under the fusebox is unscrewed - but the bolts holding the floor panels in are being stubborn as hell.

I can pull the tunnel panel back using the flex inherent in the material and can just about get to the top 4-5 bolts, so will see how it goes when it goes back in tomorrow....if it is still a faff to get to them, I may have to massacre the floor panel bolts and remove the tunnel panel completely......

zeaphod · Mar 4, 2017

Drill/grind off the floor pan screws/bolts and replace them with stainless - makes life easy next time, and makes it easier to get at the bellhousing now.

Bellhousing Bolts - 300Tdi - LT77 - 2.5NA Bellhousing (I think) - How????

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