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  #1  
Old November 19th, 2017, 05:50 PM
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ZF auto conversion - lots of questions

I am getting ready to take the plunge on a 4HP-22ZF auto / Borg Warner T-case swap in my 110. I should have done this along with the install of the new 3.9 this year but wanted to drive it a little more with the LT77 before making a decision. I don't do a lot of off-roading (mostly beach) so I am not too worried about ditching the LT230 either - I just want more highway comfort and there's a lot of slop in the current setup.
I think that I have all parts but want to know what else I may need.
I have ( all from 95 RRC):
Auto trans with torque converter
Flex plate
BW T-case
Trans linkage with shifter
T-case linkage with boot
Front half shaft
Rear driveshaft
Trans mounts
Brake pedal assembly (for wide pedal)

I will install new U-joints in shafts, new chain in T-case, etc. Is there anything else that I am missing? Any issues with using the NAS cross member currently installed?

There was a thread I can no longer find that described torque converter distance to avoid crushing the oil pump upon install - it varies by serial number? - anyone know what I am talking about here?

Finally, there are tons of pics in the auto conversion thread with pics of console solutions, does anyone have pics of the install of the trans?

As always, thanks in advance for any advice.
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  #2  
Old November 19th, 2017, 06:31 PM
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I would strongly recommend keeping the LT230 and ditching the Borg-Warner in your scenario...



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  #3  
Old November 19th, 2017, 06:40 PM
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Jeff, Thanks for the feedback. I was told that the Viscous Coupler in the Borg Warner allows faster highway speeds (not like I am setting speed records anyway) - Will the auto and 230 combo still do ok?
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Old November 19th, 2017, 06:42 PM
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All these LS converted trucks are using the Lt230 and they hold up to a lot more speed/stress than your 3.9 will ever throw at it. Who told you that? so we can publicly shame them
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Old November 19th, 2017, 06:59 PM
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Ha! Cant throw anyone under the bus but now re-thinking this. I think my LT230 has about 150K miles like the rest of the old drive train. So, any guess as to rebuild cost?
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Old November 19th, 2017, 07:33 PM
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I assume the problem is the gear ratio in your current LT230. You can change that or simple get one from a Discovery. In fact that is where you should get everything, the gearbox, shifters and so on.
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Old November 19th, 2017, 07:34 PM
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Quote:
Originally Posted by Nomar View Post
I would strongly recommend keeping the LT230 and ditching the Borg-Warner
emphaticaly

------ Follow up post added November 19th, 2017 07:36 PM ------

Quote:
Originally Posted by Noyac40 View Post
I was told that the Viscous Coupler in the Borg Warner allows faster highway speeds
Someone lied
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Old November 19th, 2017, 07:48 PM
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Thanks guys, good advice here. Is it a big deal to have the automatic lockout added during a rebuild- or is it even necessary? Also what are the best highway gears, 1.2?
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Old November 19th, 2017, 08:56 PM
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Quote:
Originally Posted by Noyac40 View Post
Also what are the best highway gears, 1.2?
Yes. Thatís the Ďtallestí geared stock option (the other options being 1:4 or 1:6, which are geared lower). There is also an aftermarked cover that increases the oil capacity. Iím not sure what the consensus is on that.
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Old November 19th, 2017, 09:05 PM
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Definitely worth a look if I rebuild, thanks
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  #11  
Old November 19th, 2017, 09:22 PM
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Any BW box still around has to have far beyond its sell by date. The LT230 can usually be picked up used with 1.2 gearing for $250 or do used.


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Old November 19th, 2017, 09:24 PM
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Quote:
Originally Posted by Noyac40 View Post
Thanks guys, good advice here. Is it a big deal to have the automatic lockout added during a rebuild- or is it even necessary? Also what are the best highway gears, 1.2?
Depends on your truck-and how you will use it. IE will you tow with it ? Tire height ?
How tall is your truck ? Roof rack ?

Most say lower rpm @ highway speed= better fuel economy. I have not found that to be true. Rover v8's seem to do well around 27-3000 rpm on high way. I have 4 v8's on the road @ present all with 1.2 tcases and 32 or 33 inch tires. They get better mileage running 70-75 than they do @ 60-65.
Will likely run a 1.4 in the one I'm putting together now on 33.25 tires for this reason. Should help with acceleration and towing as well.
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Old November 19th, 2017, 09:54 PM
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Quote:
Originally Posted by Uncle Douglas View Post
Depends on your truck-and how you will use it. IE will you tow with it ? Tire height ?
How tall is your truck ? Roof rack ?

Most say lower rpm @ highway speed= better fuel economy. I have not found that to be true. Rover v8's seem to do well around 27-3000 rpm on high way. I have 4 v8's on the road @ present all with 1.2 tcases and 32 or 33 inch tires. They get better mileage running 70-75 than they do @ 60-65.
Will likely run a 1.4 in the one I'm putting together now on 33.25 tires for this reason. Should help with acceleration and towing as well.

Mostly summer use as its a 110 5 door soft top and if I tow its just across the street to drop the boat in, not towing any distance. I am running 285 75 16 bfg's. 1.2 is what I think I have but its entirely possible that its just tired and needs a rebuild.
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  #14  
Old November 19th, 2017, 09:59 PM
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In defense of the borg warner, it is very smooth and quiet. Also has the fattest chain drive of any TC of its type so is super robust. The VC does not fail on all of them as some would make it seem.
That said, having the LT230 and the central diff lock will be far more desirable.
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Old November 19th, 2017, 10:01 PM
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Put it together with what you have and see if you like it. Pre 1996 lt230's need to be updated with a crossdrilled input gear. I swap them all out for 1996 or newer Q (quiet) suffix boxes.Transfer cases are easy to swap out if you want to switch to 1.4.
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Old November 19th, 2017, 10:14 PM
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Quote:
Originally Posted by Uncle Douglas View Post
Put it together with what you have and see if you like it. Pre 1996 lt230's need to be updated with a crossdrilled input gear. I swap them all out for 1996 or newer Q (quiet) suffix boxes.Transfer cases are easy to swap out if you want to switch to 1.4.
Thanks for that. Its true, my 97 D1 was quiet and smooth, maybe that's the answer.
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