Bell Housing Bolts

[SMLE]

I transplanted a 4.0 into my '03 4.6 Discovery 2.


I ran into an issue lining up the bell housing to engine bolts.


Put six bolts through transmission into engine. Left some play.


Installed the bolts on the flywheel / flex plate and tightened.


Now I can't get the bolts that go through the engine and into the bell housing to line up right. It's like the whole transmission is about 1/16 of an inch to low. Doesn't appear to be a rotation problem.


Did I make a mistake when I tightened the flywheel bolts before finishing loosely installing all the bell housing bolts, or could be something else be going on?

 

[jymmiejamz]

Do you have an extra dowel stuck in the block or bell housing? I always bolt up the torque converter last.

 

[SMLE]

No extra dowel.


Went ahead and pulled the motor back out.


Looks like all the bolts on the block lined up correctly, but the bolts going through the oil pan and into the transmission are slightly off.


I'm thinking it may be because I was too cheap to buy a new oil pan gasket for this experiment and used permatex instead. Looks like it may be a little too thin and not allowing the oil pan bolt holes to line up.


If I'd realized that before pulling the engine back out, I would probably have just left those four bolts out for now until I determine if the 4.0 will run in the 4.6 Rover.

 

[number9]

Put six bolts through transmission into engine. Left some play.

Installed the bolts on the flywheel / flex plate and tightened.

Tightened flex plate bolts would've defeated purpose of play in housing bolts. Did you try loosening prior to pulling engine? May be gasket as well and best not to be too cheap.
......

 

[jymmiejamz]

I'm thinking it may be because I was too cheap to buy a new oil pan gasket for this experiment and used permatex instead. Looks like it may be a little too thin and not allowing the oil pan bolt holes to line up.


If I'd realized that before pulling the engine back out, I would probably have just left those four bolts out for now until I determine if the 4.0 will run in the 4.6 Rover.

So the only issue you are having is getting the bolts on the oil pan to line up with the bell housing? Just leave them out. Before the DII, Rovers didn't have bolts from the oil pan to the bell housing. Not using the correct oil pan gasket could definitely cause this.

 

[rovercanus]

You will be way disappointed in the performance of the 4.0.
I'm also curious why you didn't tighten the bell housing bolts before the flex plate.

 

[SMLE]

So the only issue you are having is getting the bolts on the oil pan to line up with the bell housing? Just leave them out. Before the DII, Rovers didn't have bolts from the oil pan to the bell housing. Not using the correct oil pan gasket could definitely cause this.

Yep, should have just done that instead of pulling it back out...


This is my first foray into Rover engine swaps/rebuilds... Didn't realize what the problem was until after I got it back out and looked everything over.

You will be way disappointed in the performance of the 4.0.
I'm also curious why you didn't tighten the bell housing bolts before the flex plate.

I'm sure I will be disappointed in the performance. But considering that the 4.6 originally in the vehicle has a cracked block and the running 4.0 was just sitting on an engine stand doing nothing, I'll probably be ecstatic to get the '03 D2 back on the road for next to no cash outlay. At least that's what I'm hoping.


.

 

[KyleT]

The oil pan gasket has the anti crush spacers so yes that's the issue.

The power loss will be noticeable.

 

[jymmiejamz]

I can't tell the power difference between a DII with a 4.0 vs a 4.6 if both are stock. I know there is a difference, but I think it is pretty slight.

 

[rovercanus]

I can't tell the power difference between a DII with a 4.0 vs a 4.6 if both are stock. I know there is a difference, but I think it is pretty slight.

That's because you are numb all over.

 

[jymmiejamz]

If its not a 5.0 supercharged Jag motor, then it is unbearably slow.

 

[aliastel]

I can't tell the power difference between a DII with a 4.0 vs a 4.6 if both are stock. I know there is a difference, but I think it is pretty slight.

I found a nice fresh 4.0 in my D2 had plenty of power for the job. Didn't really notice much of a difference between that and the 4.6 running Lucas injection, a dizzy and Crower cam in my RRC. Of course, a 4.6 with the Bosch injection may do as well.