Where to find help when you want to change major units on your CF - engine, transmission, brakes etc. - or upgrade earlier models to later specifications.
camper23
 
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Hello all

I am sure this has been thrashed out many times but I want to be clear before I commit pennies to further work.

I have not had the opportunity to look at my campers gearbox which I want to do before it is used in earnest for long trips but getting parts is as we know a problem. Currently I have two Vauxhall gearboxes both needing attention in some way. (I have posted before on one of the problems whine on overun ) The other has syncromesh problems. Before tearing them down and maybe canabalising one to make up another or expending cash on repairing them (if possible that is) I am pondering fitting a 4 speed ZF box from a 2.3 CF 1980-84 and having done with it, as the camper even when not fully loaded weighs nearly 2 tonne which is quite an ask for the vauxhall gearbox which I believe was designed for a car! The ZF box in question unfortunately is bare, no bell housing clutch mech etc. etc.. I was wondering if the ZF will accept the vauxhall bell housing and associated bits ? I imagine a new propshaft will also be required as it is I believe flange mounted on the ZF unlike the vauxhall.

I imagine it can be done but it's a case of weighing up the pros and cons and cost. Any pointers would be appreciated.


Cheers

Alan

Postby camper23 » Tue Aug 01, 2017 2:10 pm


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Phil Bradshaw
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ZF transmission will require the clutch housing for ZF for the 2279cc Vauxhall OHC ('slant') engine and the clutch fork to go with it.

If the transmission you have did come from a Vauxhall OHC engine then that's half the battle: input shaft should be the correct type. (ZF from Opel CIH petrol or GM diesel has a longer input shaft as well as a different clutch housing)
    What is real is not the external form but the idea, the essence of things. Constantin Brâncuși

Postby Phil Bradshaw » Tue Aug 01, 2017 6:27 pm


camper23
 
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Hi again thank you fro the reply.

Bugger!

It seems that it will be more difficult than I had hoped. I guess it is a case of keep on the lookout for bits and hope they turns up.

I guess it's propshaft, clutch fork, bell housing speedo cable, gear lever and cross member will have to be sourced. This might be a long term project I think. But the rest of the camper is worth it. Hopefully?

If I can't source the necessaries i might have have to take the plunge this winter and canabalise the two vauxhall boxes.


Cheers again

Alan

On a separate note I have just replaced the old 28 amp AC delco alternator which was leaking current via the voltage regulator and slowly flattening the battery with a brand new 45 amp Lucas ACR type copy from Bull motif spares ltd. They are a mini specialist but the lucas alternator fits perfectly (once you have converted it to a LHS mout by swivelling the casings). And at a price of £43 inc vat and it comes with fan and pulley it seems a good solution to fitting a second hand unknown unit. The pulley is a tad smaller but does not seem to have made any difference. So far its working well and the wiring alteration is minimal.

Postby camper23 » Wed Aug 02, 2017 10:22 am


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Phil Bradshaw
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Cross member is the same apart from very early models where the cross member is bolted directly to the chassis brackets.

For short wheelbase models spacer brackets about 1 inch deep are required each end so that the ZF transmission clears the cab floor.

Best of luck with your quest. :thumb:
    What is real is not the external form but the idea, the essence of things. Constantin Brâncuși

Postby Phil Bradshaw » Wed Aug 02, 2017 2:39 pm


camper23
 
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Thanks for the tips.

Just a thought if I change the gearbox the clutch will need changing as well. It is getting a bit long in the tooth anyway.

I think it is an 8 1/2 inch clutch plate on the 1.8 slant flywheel with a spline to suit the vauxhall 4 speed.

I assume I will need a new plate cover and release bearing to suit the ZF box? But what do you look for? most of what I have seen for sale seem to be for vauxhall or other boxes. Is there a specific clutch kit I should look for.

Cheers

Alan

Postby camper23 » Thu Aug 03, 2017 7:39 pm


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Phil Bradshaw
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If you're intending to replace the 8.5-inch with a 9.5-inch clutch then the larger unit will need a flywheel to suit drilled for the 6 cover bolts and 3 locating dowels.

Clutch disc hub splines are the same. Clutch housing for ZF transmission has no provision for using the 8.5-inch clutch fork.
    What is real is not the external form but the idea, the essence of things. Constantin Brâncuși

Postby Phil Bradshaw » Fri Aug 04, 2017 3:44 pm


camper23
 
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Thanks again Phil

That is good news about the clutch splines! So a Standard CF clutch should do the job. 2.3 or 1.8 vintage.

I must admit I am not 100 percent sure about the 8.5 inch clutch in my 1.8 . It could be a 9.5 I just do not know for sure till I take it off. But the 2.3 engine engine that was the donor for the four speed gearbox now in the camper (which has the bad whine) has a 9.5 inch ( well the cover is marked as a 9.5/9 type) clutch. And from memory they looked the same as the 1.8, but I can not swear to it. Also I just remembered this morning that when I put the the 4 speed vauxhall from the 2.3 on my 1.8 camper I had to change the bell housing as the clutch fork is the "pull" type on the 1.8 not the "push" .

So when I fit a ZF box, will the release bearing and fork from the 2.3 bell housing (that had the vauxhall 4 speed box) fit the new ZF box and its associated bell housing? Or are the they different? I had a good look at the sequence of photos you did on rebuilding the series "A cooked engine" which has a ZF box going into a 2.3 slant and the fork looks slightly different (where the spring attaches) to the one I have. However the release bearing looks the same as the one I have though I could not see it in its entirety in the photos.

If the bearings is the same a slight mod to the fork might be all that is needed for it to fit the ZF bell housing?

I bit complex but it I can only get a slant to ZF bell housing without the exact fork, the one I have might do!


Thanks once again

Regards

Alan

Postby camper23 » Fri Aug 04, 2017 5:33 pm


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Phil Bradshaw
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Clutch release bearing for ZF transmission required; bearing assembly for Vauxhall transmission is different.
    What is real is not the external form but the idea, the essence of things. Constantin Brâncuși

Postby Phil Bradshaw » Fri Aug 04, 2017 9:41 pm


camper23
 
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Bugger ! yet again

The quest continues!

Postby camper23 » Mon Aug 07, 2017 7:59 am


camper23
 
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Well the saga continues....


I have sourced most of the bits I need I have a 4 speed ZF box which is going to need a rebuild unfortunately (have the new bearings and am going to do myself) Gear lever, bell housing, release bearing, clutch cable, speedo cable, clutch relay lever (just missing the actuator fork now). I have got a propshaft also but I have a problem. I had not realised that the drive flange on my diff is smaller than the one on the propshaft for the ZF box so I am stuffed, (again).

My Diff drive flange accepts the propshaft with a cv joint mounted on it not a UJ as on the new propshaft. So maybe I may have to graft that onto the end of the new propshaft though I am loathed to ruin what is a good vauxhall gearbox propshaft in case of future need by me or other needy CF owner.

Does anyone know if an alternative flange that will fit the UJ on the ZF box propshaft and mate with my diff flange? Short of machining one, (which would need a forging and not to mention be b***** difficult).

Postby camper23 » Sun Sep 17, 2017 12:33 pm