ZF S5-42 to LT 230.

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Originally Posted by nrs91

1.2? you worried the cummins wont pull 1.003? lol 50mm taper bearings makes sense if you can get them easy enough.

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It would pull it, but I did a whole load of calculations, and with the ZF overdrive box, 1.222:1 t.fer, 3.54:1 diffs, and 255/100 R 16's that'll give me 124kph at 2500rpm which is legs to overtake, and sensible rpm/fuel consumption between 80 and 110 kph which will be the most used speeds. Had I gone with 1.003:1 it'd have given me something daft like 156kph at 2500rpm! (Or 112kph at 2500 with 4.7:1 diffs..). I've got a 1.410 box, a 1.222 box and a 1.003 box here and the gears in the 1.222:1 box are about 10mm wider than the rest.... so deemed this to be the strongest way to go. I'm putting a one piece Ashcroft Cross Shaft in the center diff and a larger sump. It all should help and work ok. :)

Sounds spot on then buddy!

Hello all. Ok, I've neglected this thread a bit of late as I've been concentrating on the engine conversion in the 101 section, but, as the engine is about to go back in for the final time, there are lots of little jobs that need wrapping up before this can happen... This thread and conversion is one of them! Gear update. Right, the gear has been welded (finally) and Im collecting it on Mon on my way back from a mystery tour this weekend with the wife! I had commissioned him to make me a new one as he reckoned he could make me new for $1000.... Due to Land Rover using random gear cutting sizes, the machine shop is unable to get the gear cutter required and would have to make all new gears!! That tho might happen down the track as I fancy making a full time transfer case using a Salisbury 8HA center.... Anyway, here's a pic of the conversion plate top support, something that's been needing to be done for ages. I kept walking past the box trying to decide how the neatest/simplest way was going to be to do this.. and here it is. Once I have the gear back, there'll b a few close ups of that, and then a pic of it in place to show how it'll protrude out of the LT230. :)

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Originally Posted by Sitec

Anyway, here's a pic of the conversion plate top support, something that's been needing to be done for ages. I kept walking past the box trying to decide how the neatest/simplest way was going to be to do this.. and here it is. Once I have the gear back, there'll b a few close ups of that, and then a pic of it in place to show how it'll protrude out of the LT230. :)

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Salisbury centre? glutten for punishment you are mate ;)
nice fab work bud, the bracket is similar to how mine turned out.
Got a pic from the side? i want to see the spacing and clearances on the casing :)

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Originally Posted by nrs91

Salisbury centre? glutten for punishment you are mate ;)
nice fab work bud, the bracket is similar to how mine turned out.
Got a pic from the side? i want to see the spacing and clearances on the casing :)

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I'll get one up on Mon avo as Im away for a few days. Hopefully I'll have the gear then too!! :)

ideal buddy enjoy ya weekend!

At long last, here it is! The 'modified' gear. The LT will now mate to the ZF and drive! How long for is anybody's guess!! ;) The guy who did the job said that the two materials welded very nicely, and he has managed to get the weld right thru the two pieces, and said that he was quite confident of its strength. I'm now a lot happier than I was originally, as this was always going to be the weak link in the whole conversion. Time will tell how strong it is, but we have a starting point! Opinions welcome as long as they're all positive!!! :D

Looks good, fingers crossed about its longevity. Just don't break it before Melrose...:D

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Originally Posted by bacicat

Looks good, fingers crossed about its longevity. Just don't break it before Melrose...:D

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I hope not to break it full stop.... but will be gutted if it breaks before, during or after Melrose!! It does look to be a good job, and I still think it has better chances than a weld over a smaller radius spud shaft. Light throttle in 1st and 2nd gear will be the order of the day anyhow with an engine of this size. :D

Looks good, now to see it all built up and in the truck!!!