Z32 gearbox on a S13 with ca18det

[shogun!]

Hi all.
I have made some tuning on my car and would like to share some of it with you all. I try to upload lots of pictures, some descriptions and information about where to find parts.

This is how I rebuilt a Z32 gearbox to fit my car (200sx S13 with ca18det).

Yes I know it is PS, we have winter here now, hence no photo...real thing in garage is further down in the thread

The good thing about it is that you can reuse the nice clutch you already invested in for your S13. I have a twin disc OS Giken clutch, bought for my S13 gearbox. Both gearboxes have the same dimensions on the ingoing splined shaft, release bearing, sleave etc. This makes it an absolute fit. The gear ratio is slightly higher. My car had before a top speed of 282km/h at 7800rpm. With the ratio of the Z32 gearbox and new tyres it will make aprox. 305km/h. Hope you like it.

Clutch: Same as S13 (clutch, bearing, release sleave, starter motor, flywheel)
Weight: A bit heavier because of internal dimensions
Length: A bit shorter (reuse the yoke from the Z32 and the rear part from theS13 and make a new, longer prop shaft)
Gear ratio: A bit higher (~5%)
Shift stick: Reuse the one from Z32 or buy a new short shift
Welding in cast aluminium: You need a TIG or go to a welding shop (sand blast the weld area to make it clean and easier to weld)

Z32 original gearbox from a Twin Turbo 1994

[shogun!]

Disassemble the clutch housing (Z32)


Parts to remove to disassemble the clutch housing. Not shown are the screws on the outside (remove), attaching the cluth housing to the gearbox.


Remove all screws around the cover and carefully lift it off


Remove both snap rings and the stopper ring


Be careful not to lose any important washers or shims


Important! First remove the screw, spring and ball before removing the complete interlock assembly, the ball might fall into the gearbox.

[shogun!]

Before you disassemble the clutch housing of the S13 gearbox, you have to make a centering device. Use a plexi glass plate (10mm) and drill a 16mm hole in the centre, put the plate over the shaft (snug fit) and carefully drill 4 small holes exactly in the centre of the holes where the gearbox is attached to the motor. Remove the plate and carefully drill the holes just as big to get the screws in


Result


Remove the clutch housing from the ca18det S13 gearbox. It is more or less just to remove the screws on the outside of the clutch housing, remove the cover and one snap ring.


Remove the snap ring under the cover


Comparision between the both gearboxes. One is useless over 350-400Bhp, the other last well over 1000Bhp and more.


Use an angle cutting machine and cut off the flange from the S13 gearbox ca. 50mm, take it to a machine shop and have it grinded down to 45mm. Important to get it absolutely flat and equal all around.


Use an angle cutting machine and cut off the flange from the Z32 gearbox ca. 40mm, throw away the flange and take the rest of the clutch housing to a machine shop and have it grinded down to 355mm. Important to get it absolutely flat and equal all around.


Both parts after grinding, cleaning and reattaching the clutch housing on the Z32 gearbox

[shogun!]

Put the S13 flange snug to the Z32 clutch housing and attach the centering plate with four screws


Side view


Top view. Important to align and rotate them like on the picture

If you do not own a TIG-welding machine, you go to the machine shop again and have it carefully welded together, both from the outside and the inside

((((space for picture...after welding))))

[shogun!]

Reuse the shift stick bracket from the Z32 gearbox. You have to cut out some small triangles from it, bend it to a Z-shape to fit the S13 under body and then weld the cut outs together. (borrowed picture)


The new short shift


A small change of shift stick position compared to the original (borrowed picture)


A plate to cover the hole at the shift stick (borrowed picture)


A bracket to hold the gearbox in place (borrowed picture)


Aligning the gearbox with the rear axle. Put a steel tube in the gearbox, aim it towards the centre of the rear axle flange and find the final position of the gearbox bracket. (borrowed picture)


Side view (borrowed picture)


Front view (borrowed picture)


The prop shaft. Mount the Z32 yoke in the gearbox and the original flange on the rear axle. Measure the centre distance between the loops in the yoke and in the rear flange. Use this measure and go to your local prop shaft supplier and have him to make your new prop shaft. The shaft rotate at about 10.000rpm at max speed so it has to be dimensioned for the forced and also balanced.
(I will edit this post and put in a better photo and necessary dimensions)

[shogun!]

Some more parts belonging to the drive train:


Replaced the internal parts with a really good Deftforce LSD from ATS in Japan


The part number if you plan to buy one yourself. It is an easy exchange; out, move over the tooth ring, clean, mount new sealings, in, oil...ready


OS Giken Twin Disc clutch


Disassembled clutch (discs, pressure plate and flywheel in one lightweight unit)


Before switching over to five stud hub


The new hub set (is on the car now)


New rims on in the garage. Note the nice height of the fender...the 600hp engine is out meeting some new nice parts

[luisgonz]

Please dont post if you have nothing good to say about this.

[Irukandji]

Great writeup. Awesome work
+1

[revd34]

wow amazing. good job.

[shogun!]

`Shogun´ & 600hkr!

What is Need for Speed...?
A movie? A book? A game?
For me it is a feeling of controling pure, brutal power.

It all started when I had my drivers licence. I built my own dragster, a Cuda -70 with 1136 hp.

It was an awsome adventure to be in control of this extreme machine, knowing I built it myself and have success at the races. Eights on the strip, lovely time it was but rediculously expensive.

Today I´m building an extreme street racer. Handling and brutal power in a nice wraping.
Even if I am building most of it myself, it is costing a lot, but it is worth every single Krona, Euro and Dollar. Luckily there are many good suppliers around the world who produce quality parts at decent prices. I have made many good contacts during the years.

I bought the car in 1998, it was in a very good condition and more important, the engine was flawless and without errors and only a few Miles on it, just to pay.

The first mod I did was 17" rims, lowering springs and adjustable Koni dampers.
After that some styling. Got in contact with Erebuni and together we found a package and named it Shogun. They still use my car on their site.

The engine needed an upgrade. Started with exhaust system, chip tuning, open air filter and increased boost. The result was rather meager, some lousy 200 hp. Nothing to chear about. I got an intercooler, a larger turbo and a manifold. Increased fuel pressure and a modified chip. Together with some other changes, the engine produced some 300 hp... Still not satisfied.

I sold most of it.

After a heavy research I started collecting high performance parts to make it 100%. Forged pistons, forged rods, new aftermarket control unit, injectors, turbo, manifold, large IC, water cooler, clutch, oil cooler, fuelpressure regulator, blow off valve, etc etc... Bosch Motorsports added high ohm 960cc injectors from their development department. It´s nice to have contacts.
Lots of things is needed to assemble a 600hp engine.

How will the gearbox manage all those horses and the hughe torque?

The original tranny dies between 300 and 400hp...

I have to make my own.
Said and done. I bought a Z32 tranny that without swetting manage more than 1000hp.
The bellhousing was cut off and the S13 flange part was TIG welded on. A special made prop shaft and a tranny bracket was made. Thats it! OK...a short shift on top of it.

Potent engine, durable tranny...but...gripp?
How to solve this?

Bought 18" Japaneese light weight drifting rims and really good rubber.
One of the better LSD:s on the market was bought from ATS in Japan and found its place in the rear axle.
Coilovers, adjustable link/rods made of chrome molly, ball joints, swaybars...there is a long list over all modified chassie parts and upgrades.

I mounted the brakes from a Skyline, both front and rear. The brake discs got some work and the wheel hubs was exchanged to 5-bolt version to prevent the wheels from escaping during acceleration.

The interior was modified with Sparco seats, 3" 6-point belts and some more, making it able to handle and keep full control over engina data and the car handling.

It is not an easy thing to create a monster kind of car but with time and effort it is possible, but not for free. For more information, have a look on my site. There are lots of pictures, both on parts and projects.

I look forward, summer to come
`Shogun´

[projectRDM]

Originally Posted by shogun!

Today I´m building an extreme street racer

Don't you mean track car? Since street racing is both illegal and ignorant.

[luisgonz]

Wow...Street Racing Illegal . Shit Man. I wanted to race on the street.. Once again, I love the remarks. Yeah for zilvia members.

[projectRDM]

Originally Posted by luisgonz

Wow...Street Racing Illegal . Shit Man. I wanted to race on the street.. Once again, I love the remarks. Yeah for zilvia members.

No one asked you troll. Shut the fuck up.

[luisgonz]

Fuck You.

[projectRDM]

Originally Posted by luisgonz

Fuck You.

Keep it up, lock this thread too for the guy. He's really trying to show us all his 'borrowed' pics that he probably didn't even get permission to use about some shit that V8 guys have been doing for 30 years, why take that away from him?

[luisgonz]

Blah Blah Blah Thats all i hear.

[ThatGuy]

Street racing is indeed illegal and not condoned here on Zilvia.net.

Luisgonz and R240NA please take your argument elsewhere, preferably PM.

[shogun!]

and I drive my car on the street and race on the track...
...and I love every minute of it..

[big_schaf]

wow great work...but wouldnt making an adapter plate for the z32 tranny be a little more easyer?
btw what wheels are thows? i've never seen them before

[shogun!]

Thanks mate. I looked at making an adapter plate too but decided to go with the welding solution. It was easier. The weels are D2 made by Kei Racing in Japan.

[irax]

thanks shogun, keep this info up this time please!

[harlockssx]

Originally Posted by ThatGuy

Street racing is indeed illegal and not condoned here on Zilvia.net.

Luisgonz and R240NA please take your argument elsewhere, preferably PM.

Mild thread jack...isn't 99% of EVERYTHING done to our cars technically illegal? Most of the members here seem to live in California & a LOT of them have SRs...Last time I checked, drifting off of a track is illegal too, but I guarantee a majority of members here are doing it as well...

shogun! I like the car! You should show us your setup more in depth...although I do have to agree about the front bumper (I used to have a Veilside just like it myself...). Good luck with your car! Souds like you've got some great ideas & experience.

[ThatGuy]

In response to you mild thread jack:
Zilvia.net does not condone illegal activities.

[Dream240]

Originally Posted by harlockssx

Mild thread jack...isn't 99% of EVERYTHING done to our cars technically illegal? Most of the members here seem to live in California & a LOT of them have SRs...Last time I checked, drifting off of a track is illegal too, but I guarantee a majority of members here are doing it as well...

Actually you would be surprised at how much of the stuff we CAN do to our cars can be legal. As long as you comply with smog and street clearance/sound regulations, you can have alot of mods on a daily driver that won't get you busted by the po-pos. California does have alot of laws concerning car mods but most of them are reasonable and workable.

As far as the engine swapping goes, yeah that's a big hurdle, but IMO when it comes to that point for my ride...it's going to be pure track time. Besides it won't be very fun to drive on crappy California streets with our crappy traffic...

[steve shadows]

Originally Posted by R240NA

Don't you mean track car? Since street racing is both illegal and ignorant.

dude he's in sweden...

street racing is like bread and butter...

Remeber "Getaway"

lol

[revd34]

wow excellent job. ca18 parts are pentiful out their making the build easier compared to the U.S.

[shogun!]

Yes it´s true. Lately it has been easier to find good tuning parts.
Here are some pictures and names of good suppliers/brands


ProCams from Tomei in Japan


Plenum from Custom Plenum Creations in Australia


Bearings from ACL in Australia


ECU from DTAfast in UK


IRX600 Turbo from Turboservice in Sweden


JE forged pistons


Forged rods from Carillo


7-spray EV14 development injectors from Bosch Rennsport in Germany


Custom made inter cooler from Racecooling in Sweden


Custom made radiator from Racecooling in Sweden


25-row oil cooler from Setrab in Sweden


Q45 TB from Nissan


Fuel pressure regulator from Aeromotive


Seats and belts from Sparco in Italy


Gauges from Autometer


More gauges from Autometer (I have dropped the CD and replaced it with a touch screen car computer for mapping of the ECU)


I drive with the inside of my head

[shogun!]

Fitted the rail and the injectors

[EroGori]

steering wheel by tenzo in USA

[shogun!]

Found some nice engine mounts from Peak Performance.



and a new coolant can from Circuit sports.



To get the gas and fuel right, I found this Wide Band Lambda gauge from AEM.