Thread: help - cant get the gearbox back onto the 300tdi !

You need to have the gearbox in a gear (any gear) and be able to rotate the output shaft by hand as you line it up, this will rotate the input shaft to line up the clutch splines.

great thanks POD - now, how do I rotate the output shaft? undo a plate at the rear?

or turn the crank via the balancer

sounds logical thanks.

Lock the CDL in high on the transfer case and you can turn either of the output flanges to turn the gearbox.

Hope you went okay, I made the brief reply before logging off. The key is that you need everything in gear all the way through so that when you rotate the output shaft at the drive flange, the input shaft will rotate so the clutch splines can line up. Gearbox in gear, transfer in gear, diff lock in.

Originally Posted by POD

Hope you went okay, I made the brief reply before logging off. The key is that you need everything in gear all the way through so that when you rotate the output shaft at the drive flange, the input shaft will rotate so the clutch splines can line up. Gearbox in gear, transfer in gear, diff lock in.

thanks POD, went just fine mate. Only took about 20 minutes once I knew what I was doing wrong :-) I was on my own so I used a g-clamp on each side once I knew it was mated and lined up too - just to close that last 10mm.

I know it's done now, but I'll just add this in case anyone uses this post for future reference.

You can sometimes end up with the dowel in the bell housing matching a dowel on the engine, so just remove one of them, otherwise you'll be almost in and wonder why it won't budge the last 5mm.