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Thread: 300tdi Snapped Rocker Shaft

  1. 27th February 2012, 11:11 AM #1
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    brisbrain
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    300tdi Snapped Rocker Shaft

    Picked up a cheap Disco 300tdi that had cooked itself off fleabay a few months ago.
    After pulling the motor down found a few of the pistons were in a bad way so being a tight ass git put a new set of pistons and bearings in her and slapped her back together.
    I knew the head was really soft but wanted to see how long I could get out of her before I spent any more $$$.
    Well cut a long story short.... 250km was as far as i got. Was on the Bruce Highway late lastnight and bang bang bang...
    Further inspection has shown #4 rocker shaft stud stripped the threads and the shaft broke.
    Ill probably just helicoil the threads and go again on this head see how long it goes for.

    Have to say was very impressed that she managed to limp home and if any of you thought the tdi was slow you should try driving it on 3 cylinders ha ha
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  2. 27th February 2012, 03:23 PM #2
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    Seen a few rocker shafts do that on different engines, just helicoil all the threads and drive it.
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  3. 27th February 2012, 05:24 PM #3
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    I reckon torquing to specs on used and worn bolts into stretched threads causes this. If you are going to torque to factory specs, heli-coil the head rocker bolt stud/bolt holes and use new bolts/studs, otherwise do them up tight with caution, Regards Frank.
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  4. 27th February 2012, 05:55 PM #4
    slug_burner
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    might need a new rocker shaft
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  5. 27th February 2012, 07:09 PM #5
    dolphint
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    Quote Originally Posted by slug_burner View Post
    might need a new rocker shaft
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  6. 27th February 2012, 10:08 PM #6
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    glue?

    Quote Originally Posted by slug_burner View Post
    might need a new rocker shaft
    Nar! use the stick welder.
    .
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  7. 27th February 2012, 10:51 PM #7
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    Quote Originally Posted by wrinklearthur View Post
    Nar! use the stick welder.
    .
    Nah just wittle down a bit of broom handle....works every time
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  8. 28th February 2012, 08:33 AM #8
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    Quote Originally Posted by Casper View Post
    Nah just wittle down a bit of broom handle....works every time
    Ha broom handle would more than likely be stronger. Ill make sure I carry one for spares just in case this happens again.

    I remember as an apprentice forever having to carry out similar repairs to the Mercedes 103 6cyl engine. Try replacing valve stem oil seals and 24 helicoil's later the job was complete.....

    Parts ordered so will throw it back together at the weekend !
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  9. 28th February 2012, 11:41 AM #9
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    dont laugh, know someone that bought a vintage indian motorbike years ago and restored it without touching the engine, eventually it got tired and a strip down revealed 1 piston was made of turned red gum and finally burnt thru.
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