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  #1  
Old June 26th, 2016, 12:59 AM
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Gerad Davis
1967/s2a 88 200Tdi
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Solo engine install

I'm trying to install a 200tdi into my old '67 rover myself. I got everything on the back of the engine right - modified flywheel housing, 9" clutch aligned with an old input shaft and bellhousing.

I can get the engine about a half inch from mating up completely with the bellhousing studs, but I just can't drive it in any further. I suspect the input splines aren't shifting enough to align with the grooves of the clutch plate. After a few hours of reflection, I think my next step will be undoing the driveshaft, putting it in gear and giving things a twist to see if that helps. What do you guys do to help with this last little inch or two?
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  #2  
Old June 26th, 2016, 01:24 AM
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John
1985 LR 90 200Tdi
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By any chance did you change out the spigot bush using the grease method? Would the grease still be in the crank hole?
If you are within haft an inch the inputshaft splines should be into the clutch plate.

Is the input shaft you used for aligning the clutch plate same diameter as the gearbox input shaft you are fitting. Spigot bush correct size?

Hope it clicks into place without to much trouble
, good luck
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  #3  
Old June 26th, 2016, 06:02 AM
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Neil Steinhagen
1990 Perentie GS
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I struggled with this as well and found that by turning the crank shaft with a large breaker bar and socket was just enough to get things to align. I got to the point that the majority of the studs were aligned and even part way through the holes of the bell housing but no matter how hard I pushed, twisted and verbally agitated the engine it wouldn't engage. Double checked the clutch alignment, dabbed grease on the input shaft, but it just wouldn't mate. Tried for over an hour an finally gave up. Slept on it, and in the middle of the night thought about turning the crank shaft from the front of the engine. Next morning lined things up again, turned the crank about 1/2 turn, while pushing on the engine (clockwise only) and it clicked right into place.

I had the entire drive train mated before I installed everything, so I knew that everything mated up. I replaced my spigot bearing as well. But a crappy gasket between the bell housing cover and engine forced me to pull just then engine and replace the gasket.
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  #4  
Old June 26th, 2016, 08:55 AM
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Robert Davis
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The above suggestions say most everything, but I have a few questions.
Did you stay with the series transmission?
If so did you use a series driven plate (clutch disc) or one from a defender style vehicle?

I NEVER use studs they make installing the engine 10 times harder.
I take the studs out and use bolts instead.
In that way you can use varying length bolts to both align and tighten the engine up.
Putting a long bolt in each "corner lets you have the engine and belhousing completely level.
Thin with shother bolts you can pull the engine into the belhousing and have it all lined up.
With the studs if you have the engine slightly tilted, forget it...
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  #5  
Old June 26th, 2016, 10:16 AM
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John B.
1991 Defender 90, 200TDI
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If 1/2", it is the pilot bearing not going in, not the clutch splines. Tilt the engine and swing side to side, while pushing. It should go in.
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  #6  
Old June 26th, 2016, 12:17 PM
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Gerad Davis
1967/s2a 88 200Tdi
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Boom! I got it in before 9am this morning. Sometimes you just need to step away for a while. Thanks for the sounding board, fellas.

Turns out the clutch plate fell out of alignment sometime between then and now. I got that aligned and the motor slipped much closer to position. Then I used a ratchet strap to cinch it close enough to get a nut on a few of the studs and that was it.
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