300 TDi Engine Removal Guidence

Wilboro · Jun 29, 2015

So the time has almost arrived to pull the Engine/trans/tranfer case out of my project and get it ready to drop in the new chassis.

I've never pulled an engine before so I'm wondering if anyone can point me to a thread that would provide some helpful tips. Or if you have any yourself please post them.

What's coming out: A 300TDi from a 110. I'll also be removing the transmission R380 and transfer case either in one shot or after spitting it from the engine. It will need to be split regardless as I'll be re-doing the rear oil seal and putting in a new clutch.

There won't be too much in the way other than the chassis as the bulkhead will be off, no roof floor, tunnel etc. The seatbox could be removed too if it helps me in anyway.

oilburner · Jun 29, 2015

If you want a hand, I can swing by. It should be very easy with the body removed. Always easier when you have a few people to help push/pull.

Wilboro · Jun 29, 2015

That would be great. I'll get it all disconnected and then we can set up a time.

Do you think I should lift everything all at once? The crane will take 2tons at it's min extension.

javelinadave · Jun 29, 2015

2 tons, pull it out together.

oilburner · Jun 29, 2015

I dunno. If it were me, I would move the whole engine and trans over to the new chassis, then bolt the trans/transfer in, then separate the engine from the trans and change the clutch and seal. That way, the trans is bolted to something solid for removal and will be easy to line up. I hate separating engines and trannies on the floor.

Wilboro · Jun 29, 2015

Ok that's kind of what I was thinking but wasn't sure how unwieldy it would be pulled all together.

oilburner · Jun 29, 2015

With the body on, it would suck. With no body, it`s a snap.

javelinadave · Jun 29, 2015

True dat!

Whiesel · Jun 29, 2015

If your doing the rear oils seal, have you considered one of these?

Turner Engineering LUF100430 Rear Oil Seal

Just used one with success, but you might also need to drop a bearing cap if there is any sign of leakage in that area.

Eric,
Certified professional geezer

Wilboro · Jun 29, 2015

Yep that's the seal I plan to use. Did you use a gasket behind it or just sealant?

Im also wondering if I should do the crucifix seals at the same time.

ini88 · Jun 29, 2015

Took me 3 hours this weekend to pull mine. Take your hood off first

Underneath:
Undo the tranny bolts
Engine mounts
Exhaust downpipe

Ontop:
Undo the rest of the tranny bolts
Air box hoses, if they go to a snorkel
Electrics off (IP solenoid, temp, oil light, alternator, etc)
Drain coolant
Fuel lines off (to lift pump and return line)
Take off accelerator cable from IP
Fan off and shroud

You can lift it out keeping the radiator in.

6777 · Jun 29, 2015

I agree with this method, makes it easier to manage during the removal. Also since you a re splitting them anyway to replace the seals just makes it easier. You can lower the trans an T case down with a jack from below.

This is the same way i did my 200 TDI swap

ini88 · Jun 29, 2015

If you are bringing R380 and LT230 out together you will need to remove radiator, intercooler and whole grill assembly. Make sure to get a chain or strap on the south end of the R380.

I did this method when putting it in.

Wilboro · Jun 29, 2015

The rad will be coming off, essentially there won't be much in the way except the shock towers. Everything is transferring to the new rolling chassis.

oilburner · Jun 29, 2015

Do you have an impact/air?

Wilboro · Jun 29, 2015

Yep 3/8 and 1/2" guns on air

Uncle Douglas · Jun 29, 2015

I pull the entire thing as one lump. With no body on it will be child's play. I pull the bonnet and radiator support panels, floors, and tunnel. If you remove the shifter and use an adjustable load leveler its a snap

Wilboro · Jun 29, 2015

The leveller would be handy. I don't have one as of yet.

Arlo · Jun 29, 2015

Remove the body first! :thumb:

ini88 · Jun 29, 2015

Or this

Wilboro · Jun 30, 2015

Here's the current face off. I'll be pulling the bulkhead off in the next day or two (it's only on loosely after I repaired and galvanized it).

300 TDi Engine Removal Guidence

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