T244 with a ZF S6-36/2 Speed Gearbox

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magictom69
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T244 with a ZF S6-36/2 Speed Gearbox

Postby magictom69 » Sun Mar 02, 2014 10:17 am

Hi Guys,

as i wrote here

http://www.theoverlander.org/index.php? ... f=24&t=359

i`ve done it and a bought a ZF S6-36/2 Speed-Gearbox to implement in my DAF.

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This Gearbox with the part number 1290 054 086 was made for Cummins and Leyland.

My injection pump I turned and measured on the test bench. Now I have 15% more power. I notice extreme of the lower speeds and thus would have the capacity shall be sufficient for a 6-speed transmission.

Will keep you in the loop.

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Best regards

Tom

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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby crinklystarfish » Mon Mar 03, 2014 9:24 am

Looking good there Tom, you must be getting close to a 'use-able' state and planning trips?

Good information regarding the gearbox, please do let us all know how this progresses. I expect there will be a few gremlins to work out.

Were the pump modifications fairly straightforward? I've seen a couple of articles / tutorials on the internet regarding 'upgrades' but am always a bit wary of the quality of information and claimed results.

Your truck is looking very accomplished.

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magictom69
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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby magictom69 » Sat Mar 15, 2014 10:28 am

Hi Steve,

like your truck, too!

I´m not finished yet with mine, but he`s growing up step by step...

The pump modifications was done by a BOSCH-Dealer here in germany and it`s a cheap and easy thing.
Cost 142€ including postage...
This guy is a specialist from BOSCH for injection pumps and our Lucas pump is quiet easy to handle.

If you are interested or somebody else, send it and i will manage it!

The regular MOD setting is 70%, we make 85% and that keeps Cylinder head gasket and piston save.

Next week i change the gearbox and will report back soon.

Best regards

Tom

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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby Savarus » Mon Mar 17, 2014 10:09 am

Will watch this with great interest! It's looking doubtful I'll have the time, money or patience to upgrade the gearing on mine but I'm very intrigued by the idea of more power.

The truck's looking excellent by the way. Nice work that man!

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magictom69
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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby magictom69 » Mon Mar 17, 2014 7:00 pm

Hello together,

so gearbox is removed.

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After the first sighting of ZF fits perfect at the clutch housing with shaft and gear.

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That mean the clutch ever does not need changing.
But will it definitely pull off and check how far (or even if) there is wear.

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In comparison, the two gears.
Suspension from the ZF needs to be adjusted, perhaps fits when the wings are rotated...

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Exhaust needs to be changed because it was screwed on with Spicer and was conducted under the narrower gear from the leading manufactures.

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The drive shafts have to be shortened and the flange to the shaft to the transfer case needs to be changed appropriately.

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Clutch slave cylinder must be installed to match the ZF transmission from the front, instead of previously cultivated from behind

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Shift linkage is also exciting because the Spicer have the arm down and the ZF goes up.
But even more will happen until the circuit fits ...

I`m in a good mood!

Tom

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magictom69
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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby magictom69 » Wed Mar 19, 2014 6:25 pm

short update...

Transmission is ever on it ...
As written, it fits neatly on the clutch bell.

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The wings are rotated to accommodate the frame and fit perfectly to the original mounting points.
They must only be provided with a new hole.

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Problem makes the position of the clutch release mechanism, since the oil pan is in the way.
Due to the change of the disengagement from the rear to the front.

Now it will be interesting whether a civilian variant of the oil pan to the engine fits, or whether the housing must / can be rebuilt for the clutch cylinder, so that the distance to the oil pan fits again.

This is the oil pan on the civilian version with the clutch release mechanism...

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Drive train for the front axle is clean past the gear and the shaft from the transmission to the transfer case requires only the change of the flange.

So long...

Tom

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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby magictom69 » Sun Apr 06, 2014 9:33 am

Hi togheter,

so it`s done :D

The original clutch cylinder was used in the converted recording of the new transmission
and now it`s enough space to the oil pan.

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Shift linkage is changed and transmission shifts (for now without drive shaft) buttery soft.
Exhaust is off again.

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Drive shaft is expected on Wednesday by GKN and then it can go on a test drive.

Summary :

Through extensive research, the ZF gearbox with shaft and gear has exactly fitted to the clutch bell.
The existing mounting wing of the gear needed a new hole and fit again to the existing mounting points on the frame.
The modification of the exhaust is not worth mentioning . If only the position of the tail pipe at a 90 ° angle.
The problem was the mounting / adjustment of the recording of the clutch cylinder .

The existing housing has been adapted and welded that the original clutch cylinder now from the front ( instead of the current from the back) may be performing its duties .
Sticking point was the extremely scarce distance to the oil pan and without " hand work" it would not have been possible.
Tricky was the adjustment of the shift linkage , but where there's a will , there's a way ...

Had to be changed and the flange mounting of the drive shaft from the transmission side , which was given at GKN in order.

All in all quite manageable and I am the very best things that the effort was worth it!

Looking forward on a test drive...

Best regards

Tom

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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby magictom69 » Sun Apr 27, 2014 10:35 am

Hello community,

so finally it was now time and I drove the first kilometer.

Transmission shifts buttery soft and fits perfectly from the translation to the engine.

The difference in the first 5 gears is hardly noticeable, BUT the 6-SPEED... :D
82 km / h at just 2000 rpm is already now an announcement.
Have come on the road to 108 km / h and then read the traffic no longer ...

The beautiful thing is that the speed was not yet exhausted. There is still something.
At 45-50 km / h, I can comfortably insert the 6th gear and my "CARL" takes very auber to the gas and pulls upwards.

Oh what I'm looking. YEAHHHHH how horny ...

Can you recommend it only.

Shift linkage:

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Exhaust:

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Cardan shaft:

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Clutch master:

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Yesterday i drove a bit down through the area and the reduction of speed makes enormously noticeable.

As written, I'm at normal driving as not above 2000 rpm and move myself with + - 83km / h

It is very nice, at 45km / h to switch in the 6 gear without feeling that I am under motorized.

Highway driving is pending, wants to know what top speed I get.

The km / h data are all measured with GPS.

Can you tell which is 95-100 km / h already pretty violent stuff ...

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Best regards

Tom

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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby skipperted » Sun Apr 27, 2014 11:56 am

Well done Tom, great work. I won't be following your lead as I've just overhauled my gearbox, but I admire your taking on such a big job .

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Re: T244 with a ZF S6-36/2 Speed Gearbox

Postby Savarus » Sat May 10, 2014 9:30 am

Outstanding work! You must be very pleased. It's possible you're the first person to do 70mph in a DAF... and there's still some in reserve you say?! Amazing!

As above, I doubt I'll be following your example but if money & time weren't issues I'd be emailing you day & night for more detail!

Well done. This is really impressive!


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