#473 Trans to ZF Doc

[jss06c6]

Decided to pull the tranny and send it to Bill. 1st gear synch was out when I bought the car, but now 3rd is a bit rough to hit consistently. The transmission should be smoother shifting than it is. The car has a Fidanza FW in it. I've got the original dual mass on the shelf. I'll be pulling the bell housing and clutch to inspect anyway, so might refurb the dual mass and reinstall. Not worried about a few extra hp if I go back to OEM.

The C-Beam removal was a major PITA! The shifter, despite being in 3rd gear did not clear the center console tunnel opening well. Had to force it through, but made it. I'll leave the Allen bolt out on the shifter when I reinstall to give me more room to align it when I stab it back in.

So, will sit a bit, waiting for Bill to work his magic!https://uploads.tapatalk-cdn.com/20170616/c3de336eb0d0ab88f8c1b9f677edae1e.jpg

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[PhillipsLT5]

Decided to pull the tranny and send it to Bill. 1st gear synch was out when I bought the car, but now 3rd is a bit rough to hit consistently. The transmission should be smoother shifting than it is. The car has a Fidanza FW in it. I've got the original dual mass on the shelf. I'll be pulling the bell housing and clutch to inspect anyway, so might refurb the dual mass and reinstall. Not worried about a few extra hp if I go back to OEM.

The C-Beam removal was a major PITA! The shifter, despite being in 3rd gear did not clear the center console tunnel opening well. Had to force it through, but made it. I'll leave the Allen bolt out on the shifter when I reinstall to give me more room to align it when I stab it back in.

So, will sit a bit, waiting for Bill to work his magic!https://uploads.tapatalk-cdn.com/20170616/c3de336eb0d0ab88f8c1b9f677edae1e.jpg

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You will happy when you get it back, have him send you a set of his beam plates for reinstall, will make car launch straight and easier c beam install


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[GOLDCYLON]

Concur with Phil. You will be happy with the transmission and the beam plates are a no brainer. I suggest looking into Bill's short throw shifter while you are there as well.

[Racinfan83]

Ditto on the C-Beam plates....
You guys and your lifts - I'm jealous. I took mine apart and changed pilot bushing on a creeper with car on jack stands...:o

[jss06c6]

Guys,

I have Bill's beam plates. That wasn't the issue. It was getting it off after the drive shaft was removed. The tunnel space is minimal and getting it around the pinion yoke on the differential required some "prying". Also had to pry the engine/trans toward the driver side at same time. Kudos to you guys that got it done by yourself! My son was available to help me..

This is my first job on a lift. I too have done all my wrenching on my back, without a creeper and on jack stands. At 62, I decided I've had enough of that and paid enough dues to splurge on a two post lift!

The transmission is on the pallet and ready to ship..😉

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[Ccmano]

What's Bill charging for a rebuild these days?
H

[orthodoct]

Same here with the jack stands and creeper. Worked out ok except for the hernia operation that it earned me. You are right, wrestling with that beast in that tight space is a workout. Bill is THE MAN!!


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[jss06c6]

What's Bill charging for a rebuild these days?
H
Depends upon what you ask him to do.. each job is effectively "custom" work focused on the client's requirements..

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[randy ransome]

What's Bill charging for a rebuild these days?
H

My last bill was $3,400



:proud:

[jss06c6]

Headed to drop off at freight depot.. have decided to go back to dual mass FW. Luckily I bought the original one from John B. when I bought the car. Going to have it resurfaced along with my pressure plate at the guy Bill recommended. I don't have the original clutch disk, so will need to buy a new one. Recommendations welcomed!

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[jss06c6]

6255

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[jss06c6]

Clutch pulled. I see some oil weeping at the back of the crank. Very slight. Is there a seal in this joint? I see the outer seal and it's dry. This seems to be between the crank tail shaft and the flywheel ring..[ATTACH]

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[efnfast]

You got a Fidanza going in? I got one for sale if you're interested.

[jss06c6]

Sorry, no. I just pulled the Fidanza. Going back with Dual Mass..[ATTACH]

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[jss06c6]

Solved the "oil seep" situation. The prior installation had a bit too much grease loaded in the throw out bearing. When the transmission was stabbed, it apparently displaced some of the grease, which, over time, separated from heat and a small amount of oil collected. The system is dry otherwise.

The original dual mass flywheel still has the original turning finish on the face. Some surface rust from storage, but easily cleaned with scotch brite pad.

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[QB93Z]

My experience wit the C-Beam is that raising and lowering the rear of the motor makes the C-Beam easier to manage.


For install, tip the rear of the engine down so that you can slide the C-Beam onto the rear of the transmission without interference from the differential. Slide (tap with mallet) the C-beam forward past the normal position on the transmission until it clears the U-Joint yoke on the differential.


Raise the back of the motor until the C-Beam lines up with the differential, than tap it into place.


On some ZR-1's the drive shaft can be removed from the car without disturbing the C-Beam. On some ZR-1's the C-Beam has to be moved aside to get the drive shaft out. I install the drive shaft before bolting the C-Beam in place, just in case.


Jim

[G8nightman]

You got a Fidanza going in? I got one for sale if you're interested.

Is the Fidanza new how much do you want for it?

[jss06c6]

Is the Fidanza new how much do you want for it?
The one I took out is in great shape. Happy to sell mine to you. Send me a PM with your email and I'll send pics to you. Make me an offer and I'm sure we can reach a deal.

Steve

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[jss06c6]

Remember the friction plate is replaceable at a cost of about $55..

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[jss06c6]

Killing time cleaning and waiting on new clutch and transmission.. found build sheet on top of gas tank. Not worth the headache to recover it![ATTACH][ATTACH][ATTACH][ATTACH][ATTACH]

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[jss06c6]

Even cleaned and aired up the mini spare.. only had the huevos to go to 50 psi!!!

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[efnfast]

Is the Fidanza new how much do you want for it?
I bought it used and had it resurfaced. I ended up installing a Ram. $250 shipped.

[jss06c6]

Ok, back to the original thread.. Dual Mass installed. New clutch and pilot bearing. Remanufactured PP (Valeo) from Bill at ZR51 performance. Clutch disc from LUK. Ready for transmission from Bill B..[ATTACH][ATTACH][ATTACH][ATTACH]

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[jss06c6]

1st Gear Synch and other rough gears in the transmission..[ATTACH][ATTACH][ATTACH][ATTACH]

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[GOLDCYLON]

Ok, back to the original thread.. Dual Mass installed. New clutch and pilot bearing. Remanufactured PP (Valeo) from Bill at ZR51 performance. Clutch disc from LUK. Ready for transmission from Bill B..[ATTACH][ATTACH][ATTACH][ATTACH]

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You will be happy I just refreshed my clutch and hydraulic's and went back to dual mass. I hated my lightweight flywheel as the car sounded horrible unless the clutch was pushed it. Never again. Bill made it right again. GC

[jss06c6]

Good (top) compared to bad (bottom)

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[BigJohn]

You will be happy I just refreshed my clutch and hydraulic's and went back to dual mass. I hated my lightweight flywheel as the car sounded horrible unless the clutch was pushed it. Never again. Bill made it right again. GC

Now you see what happens when you get old!

[gtcollins@maxnet.co.nz]

Hi what mileage has your ZR-1 clock up
Regards Glen


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[jss06c6]

#473 is at 40,000 now..

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[jss06c6]

Got the transmission back from Bill Boudreaux and got it reinstalled. Pretty painless so far. Only thing left underneath is to reinstall the exhaust. Inside is ready to reinstall a new shift boot and button up the center console. Hopefully I'll have it on the road by this Wednesday and get some test drives in to see how the conversion back to Dual Mass shapes up. Anxious to get it on the road again!

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[jss06c6]

64616462646364646465

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[jss06c6]

Nice new badge on the transmission![ATTACH]

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[2ljd]

Nice!

Let us know how it drives/shifts.

[PhillipsLT5]

My build was # 78, 2/6/2001, 50 K miles later still smooth

[jss06c6]

My build was # 78, 2/6/2001, 50 K miles later still smooth
Great news! This is #345! Really looking forward to the first drive this week!!

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[jss06c6]

Well, today was intended to be drive day, before Harvey arrives! First issue was my 6-1/2 year old battery finally died. Got it replaced (PITA on a C4). Put in new shift boot and closed up center console. All good. Last step was to reinstall the reverse lockout and shift knob. Well, the reverse lockout knob was split at the set screw! No reverse.. ordered a replacement that should be here Monday (Hurricane Harvey permitting). I did push the car back and roll forward in 1st. Clutch is butter smooth! No noise at all in neutral with clutch engaged. Engine ran beautifully. Can't wait to get it out so I can get her to stretch her legs!

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[jss06c6]

Time to finally close this thread out. I finally got my new reverse lockout ring last night after a long delivery delay caused by Hurricane Harvey. The set screw was set in crooked and trying to remove it broke the ball end of my Allen wrench off in it! Managed to get it removed with vice grips. Replaced it with the original set screw and installed it on the shifter. Finally got to back #473 out of the shop at 9:45 last night and got out on the road. I could NOT be happier with the new DM FW/Clutch setup. The transmission is quiet at idle and launch in 1st gear is excellent.. no need to get on the throttle due to lower rotating Mass with the Fidanza setup.

Took the car out to get it up to temperature and then took it through the gears, including many pulls to 6500 rpm. The tune I've got in the car loves the new setup. It just keeps pulling hard until you get out of the throttle. All down shifts were perfect and rowing through the gears under full throttle was effortless and butter smooth.

I want to give Bill Boudreaux a very strong personal endorsement. His service level was excellent and the quality of his work, after test runs last night, is top notch. You can pay less for a transmission job, but I would caution that you get what you pay for. My desire was to get a ZF S6-40 back that was better than new and have a transmission that I could trust to be going strong for many years into the future. I got exactly what I wanted! Thanks to ZF Doc for a great experience in upgrading #473!

If I figure out how to post a link to some GoPro video, I'll do so. Time to shine her up and get back out on the road.... Next job will be complete interior overhaul with Dynamat and new carpeting!

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[G8nightman]

Nice Work!

[jss06c6]

Nice Work!
Thanks, I enjoyed the project!

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