ZF S5-42 to LT 230.

Still waiting on the Transport Mob... Forms submitted... Been told it takes two weeks to compile a list of requirements... Having been emailing a guy down there for the last 2 months, you'd think I'd have done that list... Seems they still have to take two weeks to send it to me!
As for drive, I found this on the interweb.... Several have done it the way I am planning and I've talked to a local machine shop/welder who has looked at both pieces and thinks they'll weld fine, so yeah just getting ready for when the other transfer case gets here.

with your strengthening/sandwich plate, is it steel or aluminium? If steel, is there any concern about different expansion rates due to heat compared to the other components being aluminium?

Steel, but nah, I'm not worried. The LT230 was originally bolted to an LT77 which is steel. They didn't move much. No doubt I'll find out within the first 5000kms.

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Originally Posted by uninformed

with your strengthening/sandwich plate, is it steel or aluminium? If steel, is there any concern about different expansion rates due to heat compared to the other components being aluminium?

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How hot do you want it? :eek:

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Originally Posted by Dougal

How hot do you want it? :eek:

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well it was a question not a statement, anyway, Im allowed to ask stupid questions im only a wood butcher :p

LR had problems with leaky steel sumps on the V8s, I was told expansion rates differed and this a major contributor. I dont know the difference in heat between the LT230 and the engine, But I do know the LT230 get very hot.

Id rather ask the dumb question and learn than not ask and not learn :)

I spoke to the local bearing and seal supplier today. I'm able to purchase an 'off the shelf' seal that has an o/d of 62mm to suit the LT230 casing and 50mm i/d to suit the ZF's output shaft, so no mods to the transfer box casing required. I'm also looking at the std roller bearing option on the input shaft gear in the LT230, as this will be bolted tight to the output shaft on the ZF box, which is heavily built, so would easily take the minimal side thrust caused by the helical input gear. This would make bolting the two together and setting it up much easier..

Sounds like it's all coming together mate. Great work, and all in a very short space of time - you're making the rest of us look bad...:D

nice work bud! you took to have gotten the boxes 30mm closer than ive managed so congrats!

I believe my box was shagged when I got it... if there was an award for buying the most worn out engine and box for a donor id probs win it....

however the lack of preload against the gears in the design of my conversion and my driving style probs helped the mainshaft bearings on their way to destruction. I believe the bearings have disintergrated and the mainshaft has dropped out of mesh... makes a horrid whirring noise but no go haha... the output shaft turns but not in relation to speed or gear so i believe its just "drag" caused by the horrid noises.

when ive got my shed sorted and gantry crane in ill drag the landy in and dignose the issue, improve design and fit the new gearbox

Ill pull a gearbox apart and see if theres any way to use your mounting plates without modding the LT230 and supporting the gears fully

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Originally Posted by nrs91

nice work bud! you took to have gotten the boxes 30mm closer than ive managed so congrats! Ill pull a gearbox apart and see if theres any way to use your mounting plates without modding the LT230 and supporting the gears fully

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With the transfer box in place in its std form, the ZF output shaft just slides into the LT input gear and falls just short of the LR splines. The only other way I could see to do it easily would be to source a flat type output flange for the ZF, and one of those Rakeway input flanges for the LT... but I think that'd still put it at the same distance as you have now... :)

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Originally Posted by bacicat

Sounds like it's all coming together mate. Great work, and all in a very short space of time - you're making the rest of us look bad...:D

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Hey. I'm thinking of getting him to rebuild one of mine. The one thing that I'm a bit concerned about is what engine it will end up getting.
https://www.aulro.com/afvb/images/im...013/12/194.jpg