Thread: ZF S5-42 to LT 230.

Originally Posted by Sitec

And then the sump got me thinking..... As its open in the center, there now probably wouldn't be enough support in the middle of the transfer case... especially with the extra power/torque... so I've just knocked up a 3mm plate that I'll sandwich between the sump and the transfer case. That'll stop the housing spreading!!

Good idea but probably wont without dowels

M8 bolts, M8 holes.. It'll b fine!

Can't be any worse than the standard setup, which isn't exactly famed for being flexible.

Finally got back to it today. Collected the plate from the machine shop. I've had a small recess machined into it on the ZF side of the plate, so the old speedo drive housing can sit into the plate allowing me to get the transfer case closer to the gearbox. Pictured is the plate sat on the two locating dowels of the transfer case. (It dropped straight on with no play, so I got something right!).

Here's the plate loosely bolted to the back of the gearbox. The recess on the reverse side allows it to sit flat on the four machined face bolt holes. The output housing now sits thru the plate, proud by 8mm. This will be die ground off, back to the face of the output flange seal which is recessed into the original housing by 8mm, leaving the seal flush with the plate face. The LT 230 face is on two levels. The outer bolting face, and the inner face carrying the input seal. I'm hoping to find a slim seal that will fit into the original hole, but accept the 50mm sealing face on the old ZF output flange.

Here's the third fit up of the LT against the ZF.. The first was hampered by the head of one of the M8 bolts on the diff lock side cover. The second fit up was ok, but the two casings were just touching, so a little sanding of the ZF side casing was needed...

Here's a pic of the front output housing in its final position besides the gearbox. Gives you all an idea of how close it is. I'll countersink the LT's side cover and fit countersunk Allen Head screws. The high low lever arm will also be modified. It will require straightening, and a bracket then making to carry a small air ram. Hi Lo at the turn of a switch.. Much easier!

The larger sump and one piece center diff cross shaft turned up today, so all I need now is the transfer case from Tazzie! By the time that gets here I hope to have the vehicle on the road in V8 form, run for a few weeks, then be well into the diesel fitment.