W460 rebuild + 605 conversion

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jhw.
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Been doing this for the last couple of months as and when.

Smokey old 617 ripped out and awaiting an om605/6 speed manual box.

When I got it there was some dubious previous repairs with fibreglass! (Advertised as all the welding completed lol!)

[IMG]http://i1266.photobucket.com/albums/jj529/james-w1/4_zpscxz1x6y0.jpg[/IMG]

[URL=http://s1266.photobucket.com/user/james-w1/media/3_zpso0fhazpq.jpg.html][IMG]http://i1266.photobucket.com/albums/jj529/james-w1/3_zpso0fhazpq.jpg[/IMG][/URL]

[URL=http://s1266.photobucket.com/user/james-w1/media/1_zpszwsxawq0.jpg.html][IMG]http://i1266.photobucket.com/albums/jj529/james-w1/1_zpszwsxawq0.jpg[/IMG][/URL]

[URL=http://s1266.photobucket.com/user/james-w1/media/2_zpsmhqefxpl.jpg.html][IMG]http://i1266.photobucket.com/albums/jj529/james-w1/2_zpsmhqefxpl.jpg[/IMG][/URL]

jhw.
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Re: W460 rebuild + 605 conversion

Pics that should be in first post.

jhw.
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Re: W460 rebuild + 605 conversion

Some repairs.

jhw.
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Re: W460 rebuild + 605 conversion

In paint and being built back up.

jhw.
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Re: W460 rebuild + 605 conversion

As it sits currently awaiting the 605/gearbox.

prwales
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Re: W460 rebuild + 605 conversion

without the wheel arch protectors the w463 has the earlier cars have every imaginable kind of debris flicked into the rear 3/4 by the rear wheels, good thorough job though well done

jhw.
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Re: W460 rebuild + 605 conversion

Picked a 605 engine and 722.6 autobox on wednesday night.

Yesterday I split them and fitted the slk 6 speed manual + binned the 722.6. got the engine mounts/output shaft made and fitted + dropped into the car.

Dashboard is in place awaiting final fitment.

g wagon g
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Re: W460 rebuild + 605 conversion

           Hi

Was the box out of a slk petrol??You obviously know but just a tip if it was. Fill the box with oil first before fitting. The petrols dont have the off set bell housing so oil is a jack one side up job to attain the correct level of oil. If you can,,, get a diesel gearbox as the bearings and gears are about 30% larger and they stand the weight of a g wagon just fine . The bearings are bigger too. My clk petrol box soon became noisey after fitting it to my g. The rebuilt diesel box is fine after 80000 miles of off road and road use

                                                      G

JASONGDS
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Re: W460 rebuild + 605 conversion

Are you using original pump or going mechanical injection?

jhw.
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Re: W460 rebuild + 605 conversion

g wagon g wrote:

           Hi

Was the box out of a slk petrol??You obviously know but just a tip if it was. Fill the box with oil first before fitting. The petrols dont have the off set bell housing so oil is a jack one side up job to attain the correct level of oil. If you can,,, get a diesel gearbox as the bearings and gears are about 30% larger and they stand the weight of a g wagon just fine . The bearings are bigger too. My clk petrol box soon became noisey after fitting it to my g. The rebuilt diesel box is fine after 80000 miles of off road and road use

                                                      G

 

 

HI gaz,

Yes slk petrol, great tip! I am on the lookout for a c220/270 cdi box for another big power project, this is staying low power wise though so should be ok with some extra oil in.

jhw.
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Re: W460 rebuild + 605 conversion

JASONGDS wrote:

Are you using original pump or going mechanical injection?

 

No mechanical musso pump going in next week when I get back off holiday.

g wagon g
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Re: W460 rebuild + 605 conversion

It wont need extra oil but on the car it will angle the box over to filler plug side. I filled mine on car and it makes 340 ml difference in oil level if you fill it from flat compared  to fitted on car

I have a good 220 cdi box that fits with the cable bolted to side of box and gearstick. Its only done 68k so should be perfect. £175 if you want it but pus post or collect

My first option was a cheap 180 box but it soon went noisey. Then a 170 slk box and it went the same way. My g was fine with a 220 box and still is. Bearings and all seals needed are only 160 mercedes genuine

My advise is dont make gearbox mount and propshaft a permanent thing as the cdi 200 and 220 boxes are a touch longer. Not much but enough

                                                             g

 

 

jhw.
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Re: W460 rebuild + 605 conversion

Been on holiday, back this weekend building up again, takes time to do silly little jobs.

g wagon g
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Re: W460 rebuild + 605 conversion

8000 miles not 80000


Sorry about that error. I bet some thought i never stopped driving it