Thread: How would YOU go about re-fitting an LT77 into a D1?

grab the bottom bell housing bolts, go and buy some threaded rod thats about 4 feet long and of the same thread type. cut it in half and wind it into the bottom 2 holes on the outside (bout the 5 and 7 oclock positions)

run a strop over the chassis rails tying one side off to the chassis about level with where the Tcase will sit. lay it flat on the ground.

with the Tcase and the Gearbox assembled lift one side of the vehicle and slide it under

using the strop lift the nose of the gearbox and line it up with the threaded rod, then use a trolly jack under the Tcase lift it up and slide it forwards onto the rods. once youve got it started on the rods shift the strop back and support the tcase between the park brake assy and the tcase.

slide it all forwards and use a combination of brute force, the trolly jack and the strop to support the Tcase end of the gearbox as you line up the input shaft into the clutch and the spigot.

Dont be tempted to pull the gear box in place with just the bottom bolts, once youve got it in and close put the top bolts in and once youve got to box up and level if it wont slide forwards the last 1/2 inch or so (measure it all the way to make sure its square) then the clutch or spigot is holding things up.

its a lot easier with 2 friends who are good at following manhandling instructions.

thanks, so is it better/easier to do it with the wheels on the ground after sliding the gearbox/transfer under?

also, what exactly is a strop?

Originally Posted by jazzaD1

thanks, so is it better/easier to do it with the wheels on the ground after sliding the gearbox/transfer under?

also, what exactly is a strop?

I think Strop is Queensland Talk for STRAP

actually its a kind of sling, usually has an eye at each end. any decent rope will do.

and no..

the easy way of doing it is with all four wheels off of the ground with the vehicle up on a 2 post hoist supported by the chassis and the trans/tcase mounted up on a proper trans lifter.

In addition to BK's strop method : May I suggest jacking up the front of the engine a little so that you can easily get to the top bellhousing bolts. This will require loosening of the radiator hoses and removal of the fan.

If you cannot find some help nearby or think that the gb/tc assembly is a bit too big to handle in one go try this:

Using a V8 R380 in a Tdi

and go to part 3.