gear box in and out chaps ?

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lordluke1995

New Member
Posts
628
right tried coupling my 200 to my box today ( in landrover) and i got one top stud on and that was it ! there was still an inch gap at bottom, and half inch on one side, iv tried riggling etc cant get it in, i have only left like 6 studs in the dam thing , temporarily ,

was wondering if it much of a job to remove box and couple outside of truck then chuck it all in as one ?

thanks in advance
luke
 
Is it defo the studs or could it be the clutch alignment?
Could try turning the engine slightly.

But in answer to the question, yes you can install as one unit. Rather heavy though.
 
lordluke1995 said:
right tried coupling my 200 to my box today ( in landrover) and i got one top stud on and that was it ! there was still an inch gap at bottom, and half inch on one side, iv tried riggling etc cant get it in, i have only left like 6 studs in the dam thing , temporarily ,

was wondering if it much of a job to remove box and couple outside of truck then chuck it all in as one ?

thanks in advance
luke
Click to expand...
they are a tight fit and if your not careful you can pull clutch plate out of line ,clean bellhousing bolt holes with a 10 mm drill and put a socket on front pulley nut of engine ,prop gearbox up and make secure ,ensure gap is the same top bottom side to side before wiggling in while turning front pulley
 
Sometimes you get lucky and they just slip together, other times it can be a right barsteward but to get them together the gap around the bellhousing must remain the same all the way around for them to slide together.Putting box in gear and turning output flange can help get input shaft splines to line up with clutch.Two people helps a lot. Good luck.
 
right when i get back off holiday i will firsty try pushing the car in gear see if that has any help, i dont think it would be the studs if one was lined up and in ?

i havent got the right size socket ! its peed me off i know !

any other tips as i have tried 3 times with 3 different freinds !

oh and the shaft definately fits does it ? without taking shims off ?
 
what shims ? it has to be perfectly aligned otherwise you can push all night and it wont go in ,are all studs alinged with bell housing hole not one or two left in that have no holes to go through
 
no i have had another bell housing that fits on !, i mean the hole in the middle of flywheel, they hav like rings in em ! i checked with 19j which was in it and they seemed to fit ??
 
right so thats not causing me grief then !
ill get down to 1 stud then it will fit then have to fit the rest as and when !
 
dont force it as the garage must of done with mine as you will be changing it again few miles down the road ,you can damage the clutch center ond it will break free then your buggered !!!
loosen bolts , get a buddy with rachet or spanner on front pully while you and a mate riggle gearbox in and out slightly till spines lock into each over then it will slide home then bolt up (maybe fiddley but works) did for me
ensure clutch plate aligned,spigot bush to as you will be flogging a dead horse if you dont !! good luck hope this helps
 
yeh will do, whats the spigot bush, do i need a new one , and will the 200 tdi one fit the series box ?

btw im using series clutch plate and series clutch case
 
its a little copperish/brass ring that fits in the fly wheel end
gear box ????? as they are quite different but ive never tried it !!!
so cant help but someone on here will !!!
personnally i woudnt think so
 
digbymole said:
its a little copperish/brass ring that fits in the fly wheel end
gear box ????? as they are quite different but ive never tried it !!!
so cant help but someone on here will !!!
personnally i woudnt think so
Click to expand...

gearbox input shaft spigot bush in flywheel
 
right do i need to change anything or not ? i know what your on about now as i broke the 19j one before

could shaft be sticking proud ? i tryed to get bell housing off but couldnt so put it all back as i found it ?
 
interesting you say that i did jack it up but didnt slaken mounts, will give this ago next week,

btw anyone want to buy a 200tdi series 88 in black :D i want a disco much nicer :), failing that a range ;)
 
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