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Biotoxic

ZF6HP26 Gearbox upgrades and torque converters..

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Hi folks, since I have a "cattle grind" effect(rpms flactuating  while cruising, but not in a MS mode) I came to to conclusion  that a torque converter  needs to be refurbished/uprated. Found a company  called Sussex autos, they also uprates/reinforce the TC locking mechanism(or something  along those lines) 

Since the gearbox oil will have to be drained and new sump pan fitted anyway I thought that I could Google the other stuff that I could change it while at it. Besides mehatronic sleeve and other gaskets seals I found complete refurbishment kit/kits. Some of them comes with a nozzles(or something  like that)and some don't, fair enough. Then I stumble upon different  articles regarding this gearbox like stage 2 exedy sport clutch package that fits zf6hp26 AND 6R80(gearbox wich is a uprated gearbox but from Ford, straight fit would be nice..). Then there is a company  in Autralia or NZ that does a uprated gearbox internals like drive shafts and other parts including TCs.... Anyway. . Has anybody bothered  here to upgrade/uprate the gearbox for 535d? Got a remap and all but the gearbox and the TC is a limiting factor at the moment. I could change the oil and the TC + the seals/gaskets for the gearbox itself  but for a extra £450 from exedy I could  improve the gearbox so it handles close to 900-1000Nm instead of standart 700 Nm..

 

The other thing, is there a trader here or somebody else who could point me to the right direction where to get the ZF longlife 6 (or something like that) gearbox oil? I think I need a 10 litres of that stuff.. offcourse with a member  discount  and all.. Not too keen on ebay as one seller was offering 10 litres for £104 and the other one just offered 6 litres for £94.... something dodgy  over there.

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Getting the TC refurbished will make a big difference. However if you're up for it all the other clutches are are likely to be worn too. An upgrade kit, I assume, will replace all your worn clutches. It's quite a big job changing all the clutches, I think there are 7 with something like 6 friction plates each. Lots and lots of parts to carefully remove and replace.

 

The TC does go on the 535d but not many have had other gearbox issues, even on mapped cars due to the extra power. Most gearbox issues seem to be down to low oil, need for an oil change or a worn TC. There are exceptions, but very few.

 

As for the oil ZF LG6 has an RRP of around £20 a litre. A few years ago some places would sell it at trade price, around £5 a litre, but then I think ZF stamped down and won't supply anyone who sells it cheaply.

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49 minutes ago, 535i Andrew said:

Up to £3k will be needed to refurb a 6HP box.

 

The oldest E60s aren't worth that price.

 

Its why I have an F10.

This would  be a diy project.  Doesn't  look too difficult it's  just the downtime  that concerns  me. If a ford gearbox is a straight  fit, I wouldn't have to rush anywhere and slowly build it myself. Had a pleasure to strip the engine and put everything together and it worked. Gearbox looks easy enough to do at home...

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The 6HP boxes are solid. Whilst you can go with the Exedy upgraded plates, the standard box in good condition does not struggle to hold on to over 900Nm providing it doesn't come in one huge lump. There's a few engines knocking out north of that now, mine included. I've done an oil and filter change twice on my box and that's it. The original one with  (as of tonight) 141k on it.

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17 hours ago, 535i Andrew said:

Up to £3k will be needed to refurb a 6HP box.

 

The oldest E60s aren't worth that price.

 

Its why I have an F10.

My fear with that statement is, you could be selling a good car with one issue for one with loads of inherent problems... I intend on keeping my 535d for a long time as I managed to buy one that has zero issues (a rare thing). So i would get the gearbox fixed

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5 minutes ago, Blobby said:

you could be selling a good car with one issue 

 

An E60 with one issue? 

 

16 minutes ago, 535i Andrew said:

Oh Yeah?  You not been on this forum long? Lol:D

 

Sorry, joking aside you are right.

 

If you know it's s good'un then it's up to you to get fixed. 

 

The wife put it to me as it's £3k towards a new car, and after a gut wrenching decision to part with my V8, it went. 

 

 

 

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In the scheme of things, my 530d has been very good, with only a failed alternator, so I'd also get my gearbox rebuilt

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Did a quite a lot of "deep web" digging,  a lot of coffee,  long nights finding all the info.. now I more or less got it.

Soon to be continued in my projects thread.

There is one thing that I need help with.. Maybe somebody  had to deal with someone who specialises in gearbox parts, could be in scrapyard  or online shop. I need some parts from a Ford gearbox.  To be specific  a 6r80 gearbox. The OEM ones cost quite a lot... don't  want to spend aprox $900 for a input shafts and about $300-450 more for three other bits.. 

 

I could source everything  else, but at the moment I can't find those parts. If I can't  find them, there is not much of a point to uprate the gearbox although it has done 207k miles (mostly motorway tho)...

Edited by Biotoxic

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