G-wagon conversion.

robparker

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Here are a few pics of my friends recent g-wagon conversion.
Now has the 606 turbodiesel in it, still with its original fly-by-wire injection pump and smart key/steering lock/ecu system. Manual gearbox and now drives how it should have done before (had the old 5-cyl 617 engine in before)
Conversion took aprox 1 week.


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prwales

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Here are a few pics of my friends recent g-wagon conversion.
Now has the 606 turbodiesel in it, still with its original fly-by-wire injection pump and smart key/steering lock/ecu system. Manual gearbox and now drives how it should have done before (had the old 5-cyl 617 engine in before)
Conversion took aprox 1 week.


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541792_10152731494510623_728643977_n.jpg

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It looks very neat, can I ask about the cost, and was the original gearbox retained,

thanks
 
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robparker

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Well cost was just parts as he did it himself, although in the end it will be offered as a conversion to the public at a price to be determined.
It uses a getrag 5-speed manual box. The 6-speed was considered, but it was calculated that 1st was too low to be useful, and with the slightly bigger wheels on this G, 5th is higher than 6th on the other box.
There were also no mods made to the chassis, turbo or sump, unike other people that have done similar conversions, and because its retained the original fly-by-wire pump rather than everyone else who fit the older mechanical pump, it has much better low down torque.
 

NW_Merc

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As others have said, thats a very tidy job and the addition of the newer key as well. Very impressive.
 

prwales

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Well cost was just parts as he did it himself, although in the end it will be offered as a conversion to the public at a price to be determined.
It uses a getrag 5-speed manual box. The 6-speed was considered, but it was calculated that 1st was too low to be useful, and with the slightly bigger wheels on this G, 5th is higher than 6th on the other box.
There were also no mods made to the chassis, turbo or sump, unike other people that have done similar conversions, and because its retained the original fly-by-wire pump rather than everyone else who fit the older mechanical pump, it has much better low down torque.

that sounds a much more cost effective conversion than some other are considering at the moment involving a 6 speed box, I look forward to it being available to the public
 
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robparker

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People automatically assume more is better when its not always the case!
 

NW_Merc

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Does it have better power output too?
 
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It certainly has much better low down torque than when the 606 turbo engine is used with a manual 606 pump, which as far as I know all the others have been so far. Would be interesting to put both on a rolling road to compare. Over the next week or 2 we should have some MPG figures too.
 
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Im sure they're not! But you cant please everyone.
I havnt read it, but the fact that the fly-by-wire can now be used doesnt rubbish mechanical pump versions, certainly the mechanical engines will be easier to fix by people without the facilities of computer diagnostics, but then on the other hand the electronic pump means you get factory spec performance (minus engine wear) and a constantly adapting fuel system like it was designed to be in the first place, and the mechanical installation is easier.
So each to their own, doesn't bother me either way!
Its something thats been done, so I have posted it!
 

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a 606 turbo with a manual gearbox???? if only id bought a 210 with a good engine..........
 

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The most difficult part of that job will be sourcing the getrag 5 speed, assuming it's a 265. I fit these to 113 pagodas and they're like the proverbial rocking horse poo.
 

prwales

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standard gearbox in the diesel g-wagen and its in my ge300 petrol too
 

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Im sure they're not! But you cant please everyone.
I havnt read it, but the fact that the fly-by-wire can now be used doesnt rubbish mechanical pump versions, certainly the mechanical engines will be easier to fix by people without the facilities of computer diagnostics, but then on the other hand the electronic pump means you get factory spec performance (minus engine wear) and a constantly adapting fuel system like it was designed to be in the first place, and the mechanical installation is easier.
So each to their own, doesn't bother me either way!
Its something thats been done, so I have posted it!

They're going on about oil starvation, however do the majority of g class owners really use them for extreme off roading?
 
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robparker

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Oil starvation?! No! The engine mounts are "off the shelf", mercedes made this model in LHD form very briefly, the engine sits exactly where Merc designed it to fit originally.
Ah well!
 
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the g gearbox options.
the standard getrag used here is the standard 200 230 123 box which is structually the same as the early 230ge box.
the g box has breather pipes and a different prop flange which fit the car box. the g box speedo drive is left blank while the later models have a plastic plug fitted to a car casing. costs a couple of quid for m-b. 5th gear 0.812:1

the later g like the 300ge use a version of the 124 box also fitted to 126, 201, 4matic manual.
internally they are all the same and fitted with plastic speedo plug. the rear mounting is in the same position as the 123 box but the prop flange is 3 inches further foward making prop longer so more standard props will fit.
boxes upto 82 to 87 have a 5th gear of 0.812:1 and after 87 is 0.77:1.
with the later box on a g with 30" tyres,the motorway revs while cruising are within 100rpm of an e class auto in 5th.
strenght is not an issue as 300 petrol an 300td have similar power outputs.

the standard c class manual is an improved 124 box. the rear casing and mounting are different.internally they very similar with the c class box having more plastic parts replacing metal ones.
the smoother selection is mostly down to selector mechanisum and rods. this system can be used on all boxes with no box mods.
 


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