Series 3 Rebuild - 200tdi eng fit

[Chilly]

Hi All,
Finally started...again...on my series 3. Having already done brakes, bears and axles etc...

Well here is a few photos.....

http://i299.photobucket.com/albums/mm313/chilly_0706/DSC_0001.jpg

Back in Wodonga, Victoria

http://i299.photobucket.com/albums/mm313/chilly_0706/DSC_0588.jpg

Front off

http://i299.photobucket.com/albums/mm313/chilly_0706/DSC_0595.jpg[IMG]

Bulk head coming off

http://i299.photobucket.com/albums/mm313/chilly_0706/DSC_0600.jpg

Now for the engine and box

Not sure what to do with the box/transfer...rebuild or replace. Already have the 200tdi engine...What are peoples thoughts?

What do people on here do with cleaning the chassis and painting?

Going to lift the tub off later...might as well whilst it is this far apart.

Any thoughts or ideas on things I should do whilst at it.

cheers,
Chilly

[Wallydog]

Gday Chilli,
Im reading that the series gearbox is good to around 120HP. If you have a suffix D box that may work ok but I wouldnt use anything less . it seems a 2.25L petrol eng is enough to mangle their gearboxes at times.

Looks like the gearbox has been given a workout with a holden engine which makes me think get another stronger box. Or suffix D might be ample with an overhaul. Anyway you look at it its big $$$, but you never know your luck it might be for the most part ok? W.

[Chilly]

Cheers Wallydog,

I'll have to look at the gearbox to see which model.

I think the series had a good owner...once...but the last owner just drove it and thrashed it...not much tender love...o well.

Chilly

[NiteMare]

i've used my series3 box just as i got it for the last two years behind my 200tdi (88").

this motor is my daily driver and the gearbox was well tired when i did the motor swap, hopped out of 2nd on the over run on a regular basis and lost the 3rd/4th gear synchro clips about a year ago, i just continued using it and double the clutch to help things along....

it's now started hammering the 3rd/4th synchros on the over run so it's going to be pulled out really soon before something gets drastic...

now before everybody preaches about s3 boxes not being strong enough, this motor had taken several years of abuse and neglect before i got it, it had been given at least two engine swaps prior to me getting it, it really needed a front quarter chassis (i rebuilt it), the front axle was almost scrap and had more water than lubricant in it (swapped that), the bulkhead is also closer to the texture of weetabix than steel...

i've not only used this motor on the highway, it's been in pay and play pits, it goes 'laning, it been used to tow anything up to 2.5 ton gross...

i've even sank it and drove it home 40 minutes later
https://www.aulro.com/afvb/images/imported/2011/04/75.jpg


i've swapped both diffs for 3.54 out of the disco, fitted 7.50x16 tyres and an overdrive for motorway cruising (it'll sit at 70mph happily and kiss 90mph if you're patient and brave :eek: ), until the synchros started hammering the only failure i had was when the cambelt snapped (i've not even broke a halfshaft :eek: )

so going by all that i'd guess that a gearbox properly rebuilt will last you quite a while, mine is coming out in the next week or so, i've just got to drag my spare one out of it's hidey hole so i can do a quick swap

[Chilly]

Stripped the Gearbox and transfer tonight. First glimpse all looks pretty good. Need to get it cleaned up and fully inspected.


Do any companies out there do a rebuild kit..bearings, gaskets, seals etc etc etc.



Chilly