gearbox won't go back on.

harpo77 · Dec 8, 2013

Hi all.

Just replaced the clutch fork on my 300tdi disco, used a heavy duty replacement with Mnew bearing. Problem is the box won't go back in place, used the 4 rods with nuts on, the bottom sits OK but then opens up to the top. There's nothing fouling it and it's clear all doing. Tried moving to box up and down and tilting the engine back, it's sat fine on the shaft, clutch is aligned correctly and I'm baffled. I'm obviously missing something simple. Has this ever happened to you?

jamesmartin · Dec 8, 2013

have you supported the front of engine ,a bottle jack on panhard rod to front of sump works .4 studs and nuts seems a poor way ,its easier just to push/lift it up square

harpo77 · Dec 8, 2013

The nuts and Rod are only a guide (as shown in Haynes manual), using an engine host through the door and trolley jacks for adjustment.

jamesmartin · Dec 8, 2013

dont use guides if you have engine crane just support engine tilted down at the back and guide box on by hand whilst laying on your back ,ensuring its square as you go up you can feel when input shaft enters clutch and if you engage diff lock and a high gear so you can rotate gear box using hand brake drum or front flange to align splines

Lyndon · Dec 8, 2013

Just had exactly the same problem, turned out the clutch plate splines were really tight on the shaft. Take plate off the fly wheel and try it on the box of the car. It should slip on no problem. New clutch plate sorted mine straight away!

gearbox won't go back on.

harpo77

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jamesmartin

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harpo77

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jamesmartin

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Lyndon

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