6 Engine and Gearbox
Parts required 001 plus (gearbox brackets and engine bay brace) 052,079,081-086.
6.1 Mating engine to gearbox
1. If not already fitted, lightly copper grease the pivot ends of thrust release bearing (085).
2. Place the release bearing over the gearbox input shaft and locate pivots in the release lever. Locate
the straight ends of the spring retaining clips in the ends of the pivot and rotate the cranked ends
around behind the release lever until they click into the location points.
3. Align the engine and gearbox using a jack under the rear of the gearbox to aid support and to avoid
bending the input shaft. Lightly grease the input shaft before inserting thorough the clutch (you may
need to turn the gearbox to line up the splines). Once aligned push the two units together and line up
the dowels in the engine and bell housing. Secure together with 10 of 3/8” UNF x3” with star
washers and 4 of 3/8” UNF x11/2” with star washers and 6 Nylocs and flat washers. Once connected
bolt on the bell-housing flywheel lower cover (083) using the ¼”unc bolts supplied.
4. Fit the clutch slave cylinder (086) on the bell housing; the studs should already be fitted ready to
accept the slave cylinder. Secure with two 3/8”UNF nuts and lock washers, using the lower nut to
retain the return spring eye. Take the pushrod and screw on one 5/16”UNF nut followed by a lock
washer and the pushrod eye. Push the push rod as far into the slave cylinder as it will go (this is also
pushing in the piston in the slave cylinder), before lightly copper greasing the eye and locating in
clutch lever. Push the pin through clutch lever and push rod eye to secure. Make sure the clutch
slave cylinder piston is pushed in as far as it can then adjust out nearly all the free play in the clutch
movement. Once adjusted secure the pin using two 5/16” washers and a split pin, between the
washers where the return spring is located. The other end goes to the spring retaining eye on the
slave cylinder mount.
6.2 Preparing for installation of engine and gearbox assembly
Parts required 001,053,054,055,080
1. Attach the left and right hand engine mounts to the engine with the 7/16” UNF bolts and lock
washers. If using an alternator, turn the crankshaft pulley to line up the timing marks with the pointer
and remove the two lower most bolts on the left side of the timing cover. Fit on the alternator
bracket using the longer bolts supplied. Tighten the bolts ensuring that the timing mark pointer still
lines up.
2. Screw the threaded adapter and rubber mount into the rear underside of the overdrive unit.
3. Next prepare the chassis. Start by fitting the gearbox mount cross member (001) to the chassis with
four 3/8”UNF bolts. The plate must hang down from the bolts with gearbox mounting hole slightly
offset to the left of the chassis. Then loosely mount the rubber engine mounts on the chassis with the
5/16”UNF bolts supplied.
4. If the gear lever is fitted remove this before attempting to install the engine/gearbox as it will not
pass under the dash chassis cross member.
5. You are now ready to install the engine and gearbox assembly.
IMPORTANT SAFETY NOTE
The engine and gearbox weigh in excess of 350kg. Ensure all lifting equipment is rated high enough
including all strops, chains and shackles. It is helpful and safer to have assistance to install the unit into the
chassis.
6.3 Installing engine & gearbox
1. Rig the unit to the crane using the lifting eyes on the head leaving the rear chain longer then the front
to allow the gearbox to hang low and help slide it under the bulkhead cross member.
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