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Peppy's Build Thread


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  • Member For: 11y 10m 21d
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Your kidding me JVK, was it Rollmaster? I've installed a few of the single row ones in some VE cam kits I've done.. those flops love the limiter aswell, hopefully it holds out..

Anyway, more of an update, I just spoke to Brad and have purchased, the HD chain, HD tensioner, guide pivot, crank gear, driver side chain guide, and 360* thrust... The oversize head stud washers are currently getting made so I'll get them next week

Looks like I won't be eating this week but I'll feel better that all of that is taken care of

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Your kidding me JVK, was it Rollmaster? I've installed a few of the single row ones in some VE cam kits I've done.. those flops love the limiter aswell, hopefully it holds out..

Anyway, more of an update, I just spoke to Brad and have purchased, the HD chain, HD tensioner, guide pivot, crank gear, driver side chain guide, and 360* thrust... The oversize head stud washers are currently getting made so I'll get them next week

Looks like I won't be eating this week but I'll feel better that all of that is taken care of

Not sure of the brand yet but this is the second time its happend. Previously built elsewhere but now I have the pleasure of fixing it.

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Epic build thread going on here Joe. I've just spent the last 3 days catching up on 6 months worth of build thread. hahaha. So close now. Well done mate, there is a lot of knowledge between you and your old man. So much time and effort going in to this motor, it will all be worth it in the end mate. Great work...!!!

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So it's been a long weekend, the parents went away for the weekend, how rude, there's 13 days till PP... So I had to step up and take charge

My Atomic gear arrived,

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Std links are made from ~1.3mm steel, Atomic are ~1.75mm..

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Guide Pivot

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Drivers side guide, abit more rigid

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HD chain tensioner looks identical to the Nason one??? Possibly changed the internal spring

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360* thrust bearing.. "Machined" to supply oil to the thrust side...

The hardened crank gear speaks for itself.. still waiting for the larger head stud washers... I'm only really impressed with the chain, a little disappointed with everything else.. Anyway, moving on

The good old ZF... I'm not going to do a How to guide or anything, just show some photos and give some insight, hopefully give use some more confidence... It's not overly complicated, if your mechanically minded and have some common sense you'll find your way around, if not, leave it to the experts... Here's some links that may help you get your heads around it

http://www.apra-europe.org/dateien/downloads/APRA_Birmingham_Hans-Peter_Bach_ZF_Transmissions_with_Mechatronics.pdf

http://www.xoutpost.com/bmw-sav-forums/x5-e53-forum/90167-zf-6hp26-teardown.html

https://s3.amazonaws.com/sonnax-dev/uploads/pdf/pdf/12/2011_Presentation_AutoChoice.pdf

So the whole reason this build was started is that out of the blue I started to hear a strange Whir from the box, then it started slipping into gears, then stopped engaging gears, and eventually went into limp mode, this all happened within 24hrs of casual driving to and from work 25km away..

I didn't take photos of every step, just general shots of stuff.. There were no surprises for me laying in the pan which was a relief, everything was actually extremely clean, and the fluid was still red-ish...

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Lucky I got the nizzer shaft coz my input had a nice little twist!! Surely it wasn't far off snapping

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Now the Intermediate will be the weak point but they don't make a billet shaft for the BF, only the FG which already has a thicker shaft.. So we'll cross that bridge when we get to it hey

Basically with a spotless workbench I took it apart one pack at a time, to not get confused, cable tied each pack together and layed everything out in order of removal... Washed and inspected every piece, taking note of what each piece did, changing all the seals/o-rings, pieced it all back together then blowing compressed air into each hole to checking Piston activation and return.. Then doing all the measurements to check the packs etc

Pack E controls 4,5,6 gears, it looked like it had a hard life, not a lot left of he Frictions and a few heat marks on the steels, and obviously the clearances were over the factory specs

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Pack A controls 1,2,3,4 and wasn't too bad actually, within factory clearance and the Frictions were in good nick..

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Pack B controls 3,5 and reverse.. This was the worst, some of the frictions were almost non existent, plenty of hot spots on the steels and out of the factory clearances by miles.. I suspect this was due to all the WOT 3-4 shifts??

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Pack C controls 2 and 6, it wasnt too bad either, within factory clearance and frictions looked alright

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I still need to remove pack D, change the rear seal and instal the Zip kit, but it was a constructive weekend

Thanks Joe

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Good stuff Peppy. That tensioner I thought would of at least had a (slightly improved oil feed hole) . Btw that Ls3 is a 7.0l and the t/chain kit was the one you said.

PM me your mobile and I will send a couple pics if interested.

Keep up the good work mate.

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