HELP Refitting engine to 300TDI

Jamiehol · Dec 20, 2013

I am after some hints, tips or tricks to get a 300TDI engine, auto box and transfer box back into the car.

I have the assembly back into the bay, with all the boxes attached but I just can't get it back far enough for the engine mounts to line up with brackets on the chassis, closet I can get the stud on the mounts is to within 30-40mm of the hole on the chassis brackets.

I have got the engine on a hoist and tried a number of permutations with a jack under the transfer box but what ever I do can't get the engine far enough back.

Hoping someone on here my have some wisdom or tip to get everything lined up.

The car was originally a manual but looking at the donor car the chassis brackets seem to be the same

TIA Jamie

Pikey · Dec 20, 2013

Split em and fit gearbox & transfer box. Then offer engine up. If you have gb in the right place the prop shafts will fit easily.

Jamiehol · Dec 20, 2013

Thanks for the reply, I thought it would be easier trying to fit as one unit rather than battle lining the gearbox up to the engine and then battling the bell housing bolts

Dr_evil · Dec 20, 2013

engine brackets are the same as are the crossmember mounts etc

you may just need an engine hoist with more reach but personally I'd take the transfer box off and try it like that, bit easier with just gearbox and engine as it'll be lighter for a start

good tip, remove the input gear from the transfer before refitting then you don't have to align the splines back up, slide it on then drift the input gear back in through the back of the case same way it came out

jamesmartin · Dec 20, 2013

Dr_evil said:
engine brackets are the same as are the crossmember mounts etc

you may just need an engine hoist with more reach but personally I'd take the transfer box off and try it like that, bit easier with just gearbox and engine as it'll be lighter for a start

good tip, remove the input gear from the transfer before refitting then you don't have to align the splines back up, slide it on then drift the input gear back in through the back of the case same way it came out

but you then have to be extremely careful you dont dislodge input seal

Dr_evil · Dec 20, 2013

jamesmartin said:
but you then have to be extremely careful you dont dislodge input seal

I didn't on mine but it is a lot easier than trying to twist the box by hand and wriggle it on (I didn't have a hoist to help me)

Fitted gearbox and transfer by hand just holding onto them basically

Jamiehol · Dec 20, 2013

The the host seems to have enough reach, the bit that seems impossible is getting the engine at the right height toget over the engine mount brackets on the chassis but not hit the bulkhead

landowner · Dec 20, 2013

Jamiehol said:
The the host seems to have enough reach, the bit that seems impossible is getting the engine at the right height toget over the engine mount brackets on the chassis but not hit the bulkhead

You have to put it in tilted back then get another bite on it once its in to level it up

Jamiehol · Dec 20, 2013

landowner said:
You have to put it in tilted back then get another bite on it once its in to level it up

It is tilted at the minute the back end of the transfer box is hanging low under the body and the engine is higher.

Thinking over a beer this evening the thought that occurred was if I jacked the front of the car up I may be able to get a better angle between the car and engine.

landowner · Dec 20, 2013

Jamiehol said:
It is tilted at the minute the back end of the transfer box is hanging low under the body and the engine is higher.

Thinking over a beer this evening the thought that occurred was if I jacked the front of the car up I may be able to get a better angle between the car and engine.

Scissor jack between axle and chassis will give you extra clearance to get past axle, I drop the transfer box on to a trolly jack which allows it to roll back as you drop the engine in when its engine and boxes goin in together.
Jacking car body up is a good idea

Jamiehol · Dec 21, 2013

Will have another stab at it after Christmas, will give jacking the car up a go to see if helps.

I have tried jacking the transfer box up on a trolley jack, but it didn't make any difference unless I didn't jack it high enough.

HELP Refitting engine to 300TDI

Jamiehol

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Pikey

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Jamiehol

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Dr_evil

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jamesmartin

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Dr_evil

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Jamiehol

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landowner

Pensioner Pete

Jamiehol

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landowner

Pensioner Pete

Jamiehol

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