Thread: ZF Gearbox overhaul

to get the cooler supplied and fitted that is probably on the mark - which is why I haven't dont it yet trying to find time to do it my self.

new brakets have to be made and the hoses have to be modified and new fittings fitted, then new oil so not a bad price really; if you find someone who knows their way around a ZF post it up as I need mine overhauled.

any reputable BMW mechanic should be fine with the box as they were a common auto in beemers but it's the rest of the stuff they have to pull off to get to it that worries me to just drop it off to them.

You may even want to try Triumph Rovers Spares in Adelaide, they do a kit & is very well priced.
I did one for for my father in law's vehicle as he wanted to go from a manual to an auto (getting older) & while I was at it did the auto trans cooler upgrade.

Cheers

Thanks for the information fellas. On the subject of auto gearbox coolers I've been in touch with Allisport in England and they are quoting a price of $273 AU + postage for a "TIG welded stronger and more efficient version of the standard item". I'm checking now to see if it fits the standard mounting points.
Cheers

Hi,
I am in the process of fitting a P38 cooler after picking up a new original one from ebay.co.uk for 31 pounds (bargain!). There are a couple of threads on this site that go into the details of fitting one to a Disco and it seems the way to go is to get push-on fittings silver soldered onto the original pipes by enzed or pirtek. I have also seen threads overseas where they have used JIC type compression fittings and left the original pipes in situ and just hacksawed the crimp-on's off. I'm going to go the silver soldered push-on method myself and have just ordered a 24mm flare spanner to make it easier to get the top pipe off the gearbox as its a bit tricky to get to. I also had my transmission rebuilt recently and it was around 4k, i found a mob in Sydney who know ZF's and they really seemed to know what they were talking about. You can also fit stronger parts from a 4-HP24 and there is a mod to get lockup occurring in third which reduce's heat while towing. ZF will recon the 4HP-22 but they are in Sydney and don't remove and refit so you would have to send it down to them. I'm now running ELFMATIC G3 synthetic fluid now which was highly recommended by the ZF specialist, much smoother changes and less heat it seems. lots of useful info on the 4-HP22 on the Ashcroft's UK site, also cheaper to get a recon one sent out if you can wait for shipping etc.
Cheers
Mark

Flyshooter,
In my experiences from Allisport a few year ago, they are nice to deal with when you want something, but when there is a problem, they don't want to know you.

Just beware, you can't just drive around the corner & exchange it, & knowing their prices it's not something you can just not worry aout.

Cheers

Pete,
Could you give me some details on the problem you had?
Cheers
Allan

Allan
I have a 300tdi auto and had the gearbox exchanged with a recon'd unit from a ZF expert place in Melbourne (ATS - Automatic Transmission Specilaists). It cost me just under $3k for the shipping of the old down to them from Newcastle and the shipping of the reco'd unit up to me (and also the unit itself). This included having the reco'd setup for a 3rd gear lockup as well. It then cost a grand for my local LR mech in Newcastle to rip the old one out and stuff the new one in, so $4k is pretty much what we paid as well. I also have the P38 cooler ($100 for a spotless 2nd hand unit from LR wreckers in Adelaide) in the car as well. Did most of that myself except the new hoses to and from the cooler (Mr Enzed did that for I think $150?). We have been running bog standard Valvoline mineral based auto fluid since then.

This all occured a little over 2 years ago. Quite a bit of towing a 1.3t camper trailer, sand driving at Stockton and low range 4wding with oversize wheels (265/75R16s) and haven't had any slipping or overtemp lights since. We are just about to give the auto a filter service and possibly synthetic fluid changeover getting ready for a camper trailer holiday (about 10000k's).

In my mind the two biggest improvements for the ZF in the series 1 Discos is the bigger cooler and the 3rd gear lockup, makes towing much easier (albeit slow as the 300tdi is no ball tearer as it is).

Regards

Ian

Doesnt ZF have a shop in Brizzy?