Swapping in a ZF-gearbox on the W116 OM603 Part 1

The old automatic transmission isnt up to the task now when i got the turbo going, So in this episode i cut down a 5-speed ZF gearbox and mate it up to the old bellhousing from the car.

[@dustinubbing6722]

your shared knowledge is very much appreciated! Your 603 videos along w the turd have been a great help

[@Foffe2000]

Thanks =)

[@abdelhamidabdelnaser5237]

Very good

[@cullenmiller8170]

Finally he is back. I was wondering when I would see a new video on your project again. I’m just parting two of my W140 cars out. I wish I could have sent you a complete one. Also who needs an adapter kit if you have a tig welder. Great idea with the jig you built to cut the bell housings.

[@Foffe2000]

Yeah those W140 are starting to be quite valuable in Europe. And the adapter kit is usually a plate with dual bolt holes, and here i needed to make the bellhousing shorter than original, so a plate in between wasnt possible, otherwise those plates seem to be the simpler and better way to do these swaps.

[@brolle87]

kul att få se nya videos igen 😃

[@Foffe2000]

Ja varsågod, när man jobbar i "den stora blå hallen" så är det kanske lite skralt med projekt under vinterhalvåret =)

[@henryhelfman8478]

So to DIY a bellhousing transplant in your driveway, all you have to do is build a simple gearbox housing lathe. Clever

[@Foffe2000]

yes, but make it easy for yourself and take out the engine and transmission as one unit when doing this kind of work. Its modern times now and you shouldnt break your back for these kinds of tasks.

[@jarmominkkinen9409]

Handy man 👍👍

[@Gazika1984]

Hello..this is great transformation but what do you think about heat and deformation?you did not attach it on engine block to not damage because heat gives to it deformation if you not tight on place..thanks

[@JavierInnovation]

Great videos bro. How You put it the hidralic pump an the slave lines

[@user-xl1oz7fm9d]

Is the Mercedes 230 gearbox transmission compatible with the 603 diesel engine

[@heavy_low_n_slow]

Hi great build. Did you increase the elements in the diesel pump when you fitted the turbo? Cheers

[@Foffe2000]

Hello, yes this one rolls with a 7,5mm Dieselmeken pump. If you are interested in the different elements i got a video where i swap out some original elements for DPUK 7,7mm ones.

[@trondvidardalseng894]

Veldig informativ video. Hvilket svinghjul, clutch og trykkplate brukte du? Jeg vurderer også å bruke en ZF girkasse på en Mercedes OM 603. Automat girkassene holder og de manuelle girkassene Merceds har kan ikke måle seg med en BMW ZF girkasse.

[@Foffe2000]

Hej, jag köpte ett komplett kit med sachs 765 tryckplatta och 240mms tryckplatta och lameller. Speeding.se sålde produkten : www.speeding.nu/p/drivlina/kopplingskit-modellanpassat/mercedes-3503/mercedes-om603-om606-m104-m113-kopplingskit-240mm-800nm.html#

[@trondvidardalseng894]

@@Foffe2000 Fra hvilken girkasse kommer girskift mekanismen fra? Det er en slik girskift mekansime jeg er på utkikk etter.

[@Foffe2000]

@@trondvidardalseng894 det är egenbyggt från en volvo M40 växellåda från 1974. passar ej rakt på utan kräver mycket modifierande

[@simonimo7596]

Bonjour c'est quoi le modèle de turbo que vous avez met s'il vous plaît ?

[@Foffe2000]

i think you are asking me about what turbo i got, but to be sure you will have to write in english or swedish for me to understand

[@doktorjonsson3860]

Lite modigt att helsvetsa lådan innan man kollar att den passar 😅 Men gick ju bra även utan jigg 👌

[@Foffe2000]

Ja det är/var en chansning, Men verkstaden jag höll till i var 2 mil hemifrån så jag chansade då måtten på sprängkåpan och växellådans diametrar vart närapå exakt samma på de ställen dom var runda. Jag tror det hela gick bra.

[@MrFamas100]

Bra video! Har ett lyktglas i sollefteå om du behöver.

[@Foffe2000]

Tack vad snällt, Jag har 2 extra uppsättningar lycktor turligt nog. Men håll hårt i ditt glas för priserna på dom där går bara upp.

[@TheOnlyKontrol]

Love this type of fabrication. Where did you get that flywheel.

[@Foffe2000]

I bought it from Speeding.nu Try Speeding.co.uk if you want an english version. Its a Tenaci 240mm flywheel with a Sachs 765 pressure plate and a Sinter 6 puck clutch.

[@PuEvvSs]

Va körde du för mått när du to av svepet?? Håller på och ska ge mig an just samma grejj påmin 603a :)

[@Foffe2000]

Hej Josefine, jag tog av 88mm från bmw svepet, sedan ställde jag lådan mot motorn och kom fram till att 55mm från mercedes-svepet var lagomt båda mätt från växellådornas främre kant och sedan in mot växellådan. Med dessa två mått stämde ytterdiametrarna på båda svepen mot varandra ganska exakt på de ställen dom är runda. Dock har jag bara provkört lite grann så jag garanterar inte att detta är det bästa måtten att använda utan mät och fundera själv också vad som verkar lämpligt. Glöm inte att köpa/konstruera kopplingsjusteringskitet också , annars tillkommer beräkningar på att få lagomt avstånd på kopplingsgaffeln mot kopplingskorgen.

[@sylvestercheek8738]

I like your work. Are you available fabricate a exhaust manifold for my 1992 300sl. I’m want to add a turbo to this gasoline engine

[@Foffe2000]

oh, thanks for trusting me to make a manifold, but i got to many projects of my own unfortiently. Hopefully there is someone nearer to you that can take on that task.

[@sylvestercheek8738]

Thank you for taking time to answer. I enjoy your channel. Please continue to make those informative videos. We appreciate you

[@thetypical4044]

Where did u put the pilot bearing? Flywheel or crankshaft? Doing this transmission swap myself.

[@Foffe2000]

Crankshaft, i tought that was the only way? , since it was a automatic transmission originally i had nothing to compare against

[@thetypical4044]

@@Foffe2000 if u use the flywheel from speeding.se, with 240mm backplate. Then u have to have the pilot bearing in the crank. If use a flywheel from a sprinter, then machine it to 240mm, and make some new treads for the preasureplate. ( dont have to machine it to 240mm but then u can use sachs 765 pressure plate. Then u can have the pilot bearing in the flywheel. ) And i will recomend organic clutch. Holds better over time. With that high torque. Best regards from norway! :D

[@Foffe2000]

@@thetypical4044 Hello yeah its speedings flywheel, didnt know you could use sprinters flywheels bolt patterns on the OM60X engines, good to know! Thanks for the tip

[@harryhavblikk6947]

Show how to swap a dieselpump on om603 please!😅

[@harryhavblikk6947]

Timing swap and how i can do that!😅😅

[@g__wizz]

holy christ... wrong way to do that man. you need to maintain center when you weld it. you cant just "bench weld" those together.

[@Foffe2000]

Agreed , thats not the right way to do it, the plan was to use a kemppi mig welder with aluminium wire for spotwelding it togheter at 23:41 , but the diameters of the two parts off the gearboxes was spot in the same diameter so i winged it matching them up again. And you cant argue with the result? (se the next few videos where i testdrive it) but the right way to do it would have been to spotweld it all togheter out there in the snow so that i wouldnt risk misaligne it when i "bench Welded" it

[@g__wizz]

@@Foffe2000 im using a om 601 engine with a turned bar in place of the crank which bolts to the trans with a flange, to maintain center line.

[@Foffe2000]

@@g__wizz okey, here i exchanged the pilotbearing with a centre piece that is dubble the lenght witch i made in the lathe, nothing super more accurate than the original pilot bearing, but the added lenght hopefully helped centering it up. Ive seen people cutting down old OM60X engines and just leave the crankshaft in place to get a mock-up enginge thats a little bit easyer to move around.

[@jasonbirch1182]

Yeah. I can't believe this has the tolerance needed for a long clutch/pilot/trans life. I hope I'm wrong but.....