Transmission adapter - Page 2 - Defender Source
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  #21  
Old April 13th, 2015, 04:35 PM
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Jim, you don't need to pull the transferbox out if you only have to change the outcomming shaft seals!
To change the input seal or the O-rings of the intermediate axle you have to remove it!

What do you think about a workshop weekend in Bremen?
Food and lodging incloudet.
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  #22  
Old June 5th, 2015, 05:33 PM
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Just another tool

Well, a friend send me a link about how to maintenace this trum.
First picture of the needed helpers was this:



Looks very small and easy but in real it's a big one!

Decided to adapt it to my subframe of my vise.



This bracket will be drilled out to get some bushes in it and then welded to the ground plate.





At least this spanner will hold the gearbox and will be fine in vertical and horizotal position.



I hope.
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  #23  
Old June 7th, 2015, 03:28 PM
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Parts are almost ready to go!















But it needs a strong back to get the lump (clamped by the helper vise) into the bracket!











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  #24  
Old June 7th, 2015, 05:51 PM
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nice work arlo...I'm not sure what these tools are used for but it's fantastic that you're making them!
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  #25  
Old June 7th, 2015, 06:08 PM
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Haven't you seen him using them doing tranny and t230 installs? The right tools make them very doable for one person without fanfare.

I'm digging the custom tools. I sure missed having the right tools to pull the diff carrier bearings today. Oy.
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  #26  
Old June 7th, 2015, 06:39 PM
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Quote:
Originally Posted by cgalpin View Post
Haven't you seen him using them doing tranny and t230 installs? The right tools make them very doable for one person without fanfare.
Now I have...I guess it's all proper fixturing! I just have to study the thread more carefully.

Quote:
I'm digging the custom tools. I sure missed having the right tools to pull the diff carrier bearings today. Oy.
My bearings just fell right off the diff...sorry to hear yours are taking more effort!
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  #27  
Old June 8th, 2015, 04:30 PM
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Quote:
Originally Posted by sonoronos View Post
nice work arlo...I'm not sure what these tools are used for but it's fantastic that you're making them!
Thanks Ed!

This unit might be used to pull out the inner parts of a ZF automatic gearbox.

Sprayed the bracket today.


---------------------------------------------------------------------------------------------

I add the differential of the LT230 the vertical way when assembling it to the main housing.
This needs a safety stand!

Needed a better platform for that. My wooden construction works, but I like to get it better!



An old breaking plate got chopped a little bit, turned a round 180 so two of the four holes matches the threads.

I guess this will create a perfekt small table to let the output shaft hanging loose.



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  #28  
Old June 9th, 2015, 04:32 PM
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The small table is welded now.
It needs two rails at the bottom to balance the displaced point of gravaty.





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  #29  
Old June 10th, 2015, 05:43 PM
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Done!

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  #30  
Old June 13th, 2015, 03:11 PM
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Finally got some paint on it!



But I remembered the bracket for the ZF Autogearbox: this alowed to rotate!

I thought about this several days.
This bracket connects the didgeboo table with the front housing and will get a support to hold the necessary axle!



I hope to get it done tomorrow.
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  #31  
Old June 13th, 2015, 06:08 PM
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Great work Arlo - I love seeing the fixtures!
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  #32  
Old June 14th, 2015, 05:59 PM
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So do I, Don!

This is how it should look like today:



But the remaining material I had in stock was not comparing for this use.

So I decided to get the ZF-clamp ready.







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  #33  
Old June 16th, 2015, 05:33 PM
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The axle is ready. Found some 16MnCr4 round steel in the junkyard.



Welded to the frontflange and with a plain frontsurface I tried to figuer out the right position how to weld the beast onto the rusty profile.



I guess it will make sence to put a wheel on top?



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  #34  
Old June 16th, 2015, 09:02 PM
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of course
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  #35  
Old June 18th, 2015, 05:14 PM
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Finaly I got the parts welded.











Do you think, the wheel looks a little bit overdressed?
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  #36  
Old June 19th, 2015, 01:37 AM
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Anything worth doing is worth over-doing.
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  #37  
Old June 19th, 2015, 03:23 PM
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Paint is dry and the wheel soldered to the spikes:





Need thrust washers in 1,05 or 1,10mm.
But I didn't got them!

So it will take some more days to get the transmission assembled.

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  #38  
Old June 21st, 2015, 05:35 PM
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ZF dismanteling

Just pix



























































That was pretty much easy.
I hope to find the time to manufacture the needed special tools now.
And to get the parts together.
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  #39  
Old June 21st, 2015, 09:57 PM
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Cool. What was wring with it and what is the planned repair? And how is it so clean inside? If that simply after draining the fluid?
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  #40  
Old June 22nd, 2015, 04:36 PM
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It's just exercising for me.
The box had been opened weeks befor I got it for free. The owner found a lot of grey/black stuff all over the place.
I've found some more. But I like to clean a little bit, befor taking pix.

The seals to the governor's housing are cracked ...





... and today I found a crack inside the second freewheel.

Part# is 642. Please have a look at this overlook:
http://www.jpat.co.uk/89%20ZF%201%204HP22-24.pdf
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