Can't get engine in, bloody bellhousing

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ashleywood.ash

Active Member
Posts
558
Location
sheffield uk
Hi guys
I am trying to put my new engine in my 110. Old 200tdi out new 200tdi in but I am stuck.
I just can't get the engine to meet the bell housing.
It all seems level, the smooth section of the shaft goes in but then hits something so I can't get the splines in. I don't know what it is hitting as it should go in fine as there is nothing there? I have jiggled the engine with all my strength whilst jiggling the crank pulling to try and get the splines in but no luck.

It is in 3rd gear as that is only hear it will go in and I pressed clutch and pedal now rock hard.

Any tips. Ps I am on my own so have not got any help
 
I suggest you pull the engine out and have a look at the position of the release bearing if the pedal is hard.
 
Make sure that the release bearing is sitting with the flats inside the clutch lever, and is as far back towards the gearbox as possible.
When I last did mine I disconnected the propshafts so that the splies could freely turn,and so that I could tilt the gearbox up at the front.
That allowed me to tilt the engine down, rattle it into position and drop straight onto the mounts.
 
+1 for removing a prop.

although when I did mine I didn't disconnect the axle ends.

I couldn't get it in without jacking the front of the bellhousing up a bit
 
Gearbox in neutral and a little normal grease on the input shaft splines all help.
 
Hi Ashley NOT tryin to tell u how to suck eggs ! But have you put a new clutch in ? When I changed the clutch in my Disco 300tdi I had the same prob:mad: Ended up droping G/B again & taking clutch apart ONLY to find that the clutch plate would NOT go on to the gear box :mad: Sorted by the best tool ever invented :rolleyes: The HAMMER :eek: Must have had some burrs in the drive part of the clutch plate :rolleyes: Made sure that it slipped on nice & easy :) Back together & G/B went in no probs :):):)

Steve
 
No new clutch, I was told it had a new one fitted recently so didn't bother as engine will be out again in summer.

I'll try neutral, grease and prop shaft after checking bearing

Thanks
 
Ok I'm at my wits end.

I have checked release bearing is all the way back, I have disconnected prop, I have greased splines and put it in neutral and I have jacked up bell housing at various heights and it just won't go in.

I have rocked up and down, side to side, back to front but it just won't have it. It's making a metal on metal sound like it's hitting front of input shaft but I can't see why it just won't go in. If I jack bell housing it goes onto studs on bottom and pump side but then won't top and manifold side
 
When you bolted the clutch pressure plate on to the flywheel did you use a clutch alignment tool to make sure the clutch plate is centred on the flywheel? If you don't and the clutch plate is lightly off centre then you will have difficulties as the gearbox splines and the spigot bush need to be concentric. Also are you sure the spigot bush is ok on the end of the crank as the gearbox shaft needs to be able to slide in to it. If the 'new' engine was supplied with clutch and pressure plate fitted it is possible the plate may have been moved slightly if the old gearbox was just yanked off at a breakers?
 
Hi Ashley. I have just swapped an engine, and had similar issues. It took a couple of hours to get the new engine to line up, but once it was correctly lined up, it went together in a minute. It is going to be much easier with a bit of help - two other people to shove and rotate the engine. The engine needs to be at exactly the same angle as the gearbox, other wise it will nearly go in, but not quite, like your problem. leave the rubber mounts off to give yourself more wiggle room - and get help.
 
ashleywood.ash said:
Hi guys
I am trying to put my new engine in my 110. Old 200tdi out new 200tdi in but I am stuck.
I just can't get the engine to meet the bell housing.
It all seems level, the smooth section of the shaft goes in but then hits something so I can't get the splines in. I don't know what it is hitting as it should go in fine as there is nothing there? I have jiggled the engine with all my strength whilst jiggling the crank pulling to try and get the splines in but no luck.

It is in 3rd gear as that is only hear it will go in and I pressed clutch and pedal now rock hard.

Any tips. Ps I am on my own so have not got any help
Click to expand...

You said the smooth section of the shaft goes in then it hits, could it just simply be the splines are out of alignment with the splines in the clutch plate?

Put the box in neutral and turn the input shaft a little then try it, sometimes they just sit exactly out and won't go in. Had this a number of years ago and I just put a socket on the crank and wiggled it while someone helped me push the engine on.

Did you put a new clutch on, is the plate lined up properly?

I have done clutches on all sorts of vehicles and knowing how to line up a clutch properly and therefore know it's lined up fine I always find the wiggle treatment will get a stubborn box and engine back together. Also look at the angle of attack, it needs to be pretty damn bang on level or your not going to get it on either.
 
For what its worth my money is on the clutch plate splines not being aligned with the little pilot bearing in the flywheel, you can try till you are blue in the face but it wont go in if they are not aligned, I have often used a long socket through the clutch plate as mentioned above.
I also cut the head off some long bolts which were same diameter as the bell housing/engine fastening bolts and then rounded the top of the shank with a grinder, I aligned my engine - box and then put three of the long bolts through the bell housing into the engine and used them as guide rods when pulling the two together, still needs a bit of wiggling about but they help considerably take them out and put the correct ones in when you have it together and a couple of bolts in place.
 
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