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-   -   HPT Syborg Syclone T-56 Tranzilla Mangum AWD Conversion Begins! (http://www.highperformancetrucks.com/forums/showthread.php?t=203)

admin 08-22-2011 02:09 PM

HPT Syborg Syclone T-56 Tranzilla Mangum AWD Conversion Begins!
 
HighPerformaneTrucks.com's beloved time attack Syclone Syborg pickup truck's 4l80E built automatic transmission failed during the 2nd practice session at the Reno SCCA Time Trials recently. Both the 700R4 and 4l80E auto transmissions have proven themselves unreliable and unorthodox for road racing so we have embarked on the conversion to a proper gear box in the form of a fully built Tremec/Rockland Standard Gear T-56 Transzilla Magnum manual transmission while retaining the all-wheel-drivetrain. This involves some tricky gene splicing involving a corvette transaxle adapter, customer transfer case adapter, bellhousing adapter, custom 32 spline output shaft as well as custom billet 32 spline internal upgrades to the Borg Warner 4472 transfer case to match the output shaft of the manual transmission.

We started working on the Tilton pedal box. There isn't enough room to weld in the brackets so we fabbed up this custom clamp on bracket. It is adjustable and will not slip. Another bracket is being fabbed up to further support the pedal box. Since the master cylinders are interchangable among brands we will be re-using them from a cost savings standpoint. The pedal position is optimized for heel and toe braking.

http://highperformancetrucks.com/for...63f8dddb783549

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George at Rockland Standard Gear is currently building me a Tranzilla Magnum to hold 850 ft lbs tq and will use a 32 spline output shaft.

Transfer case has been rebuilt using billet internals including a billet 32 spline input shaft.

http://highperformancetrucks.com/for...1d0a30369b5fd2

http://highperformancetrucks.com/for...1d0a30369b5fd2

A McLoed twin plate clutch and lightweight flywheel will be used in conjunction with a Quicktime spun steel lightweight SFI bell housing.

Here are some images of the t56 transmission with 32 spline output shaft , transaxle adapter, transmission to transfer case adapter and transfer case with 32 spline input shaft. Not shown ware the McLoed Rtx Twin clutch and Quicktime SFI bellhousing.

http://highperformancetrucks.com/for...aa3f7c14e0a100

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Here is an image with bellhousing next to transmission.

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Images of twin disc clutch, aluminum flywheel and installation kit.

http://highperformancetrucks.com/for...aa3f7c14e0a100

http://highperformancetrucks.com/for...aa3f7c14e0a100

http://highperformancetrucks.com/for...aa3f7c14e0a100

admin 08-25-2011 08:34 PM

Image of Junior holding the new Momo suede racing steering wheel with integrated buttons. No the little red buttons won't be called "plaid" or "ludicrous", instead they will be used for turn signals for the time being. Eventually I'll upload some shots of it attached to the Sweet Mfg. quick disconnect on the custom steering "column".

http://highperformancetrucks.com/for...df273f24b423dd

admin 09-13-2011 08:04 PM

http://highperformancetrucks.com/for...2c42e06136da4e

Images showing the complexity of the steering shaft. The Tilton pedal box made a straight shot through the fire wall impossible.

http://highperformancetrucks.com/for...2c42e06136da4e

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You can see the steering column supports taking shape. A couple more will be added soon.

http://highperformancetrucks.com/for...2c42e06136da4e

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The steering column will be supported by both the safety structure and firewall.

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Some shots of the truck and it's stripped interior pieces.

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The steering column and steering shafts are being designed to be completely bolt in case I need to remove or reposition the steering angle.

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A shot of the quick disconnect steering wheel hub by Sweet Mfg. Zero play in this unit.

http://highperformancetrucks.com/for...2c42e06136da4e

admin 09-13-2011 08:10 PM

http://highperformancetrucks.com/for...2_itemId=12795

This is the adapter ring that keeps the transmission's output shaft properly centered to the transfers case's input shaft. The older style Sy/Ty transfer cases are narrower on the input side compared to later model 4472s.

http://highperformancetrucks.com/for...2_itemId=12798

Dash temporarily in place to make sure where to place the steering column supports.

http://highperformancetrucks.com/for...2_itemId=12801

A new bulkhead plate was fitted for new pushlock brake reservoir feed lines coming soon. The clutch master cylinder reservoir will be mounted in the empty space to the right of the brake fluid reservoirs.

http://highperformancetrucks.com/for...2_itemId=12804

Here's the steering column completed with the quick disconnect splined fitting welded in place.

http://highperformancetrucks.com/for...2_itemId=12807

Shot of the new MOMO steering wheel with the Sweet Mfg hub in position.

http://highperformancetrucks.com/for...2_itemId=12810

Another angle showing the completed steering assembly. The wiring really isn't as messy as the images portray.

http://highperformancetrucks.com/for...2_itemId=12813

Finally able to move onto the transmission mock up stage of the build. Here is a shot of the Bowtie block where the new Quicktime bellhousing and McLeod clutch and flywheel will reside. Notice the Canton remote oil filter sandwich and 12AN lines that run to the oil cooler inside the Ron Davis radiator in the back of the truck.

http://highperformancetrucks.com/for...2_itemId=12816

Here's a nice shot of an empty space where the new transmission will reside.

http://highperformancetrucks.com/for...2_itemId=12819

An extra shot of the 3 link suspension and "skinny" tires.

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In this image you can see where the oil cooler lines plumb into the radiator.

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FWIW, here's a shot of the underside of the front of the truck for those who are interested.

http://highperformancetrucks.com/for...2_itemId=12828

...and another undercarriage shot sans tranny.

http://highperformancetrucks.com/for...2_itemId=12831

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Sitting with all four wheels off the ground is a familiar scene for many Syclone owners, I'm sure.

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This is sight of my truck I'm hoping some unlucky Z06 owner will see on the road course eventually.

admin 09-15-2011 04:23 PM

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McLeod aluminum flywheel installed. Since it's a 153 tooth instead of the normal 168 tooth, we had to move the mini starter inboard to properly align and engage the flywheel when starting. Of course some massaging had to be done to the pan and reclock the starter to get it to fit right. The flywheel had to be heated up a bit to fit onto the Moldex crank hub.

admin 09-20-2011 08:05 PM

http://highperformancetrucks.com/for...DI_NOISSES_PMT

McLeod RXT clutch bolted to McLeod aluminum flywheel. Sorry about the grainy image. I forgot my camera and used an Ipad camera instead.

http://highperformancetrucks.com/for...DI_NOISSES_PMT

Quicktime SFI bellhousing mocked up. Note the white paint marks near the bottom of the bellhousing. We are going to have to trim it allow proper clearance for the front propshaft. I wonder if this will void the SFI rating. We literally have no choice.

http://highperformancetrucks.com/for...DI_NOISSES_PMT

View from below with bellhousing removed again. Man it's nice to work with the truck on a lift!

admin 09-21-2011 10:34 PM

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Okay so here is the bellhousing with notched area to clear the propshaft. Looks like it came from Quickltime this way. Finally got the right camera again.

http://highperformancetrucks.com/for...be8537e6639bb2

The zinc plated spacer ahead of the bellhousing is required for proper input shaft clearance.

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This is the new McLeod fully adjustable throwout bearing assembly. Nice parts!

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Quick disconnect slave cylinder line.

http://highperformancetrucks.com/for...DI_NOISSES_PMT

Here's how the centering ring looks inside the adapter against the transfer case.

Test fit of Tranzilla tomorrow!

Stay tuned!

admin 09-26-2011 03:57 PM

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Tranzilla mocked up to determine shifter location.

http://highperformancetrucks.com/for...be8537e6639bb2

admin 09-27-2011 02:30 PM

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Peeking through the modified transmission tunnel is the shifter with reverse lockout. Yes the hole will eventually be trimmed to match the aluminum cover plate.

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I have to fix this wiring mess soon.

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Custom solid transmission mount.

http://highperformancetrucks.com/for...be8537e6639bb2

We adapted it to fit to the 4L80E crossmember.

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Another angle.

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This is a custom one off shift knob milled from a piece of solid Delrin with O-rings added for better grip with race gloves.

admin 09-29-2011 08:59 PM

http://highperformancetrucks.com/for...be8537e6639bb2

A custom remote shifter system nicknamed the "gear banger" had to be built. On the stock Tremec Magnum there are three shifter location options with two normally sitting on the tail shaft. However in our AWD setup those optional shifter locations are gone as the 2WD tailshaft has been swapped out in favor of the Corvette transaxle adapter.

http://highperformancetrucks.com/for...be8537e6639bb2

It took some trial and error to get the geometry right so the shifter would engage the gears correctly.

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The shifter lever was designed so the shifter knob would be positioned close to the steering wheel as possible so I could get my hands back on the wheel quickly similar to a sequential shifter. Btw, mounting the shifter lower would cause interference issues with the race seats. I named the shifter lever the "turkey baster" .

http://highperformancetrucks.com/for...be8537e6639bb2

The shifter has an extra adjustment position if shorter shift throws are desired.

http://highperformancetrucks.com/for...be8537e6639bb2

A custom aluminum center console panel is being fabricated to fit the battery cutoff switch and other functions. The four hex head bolts are only for mock up. Trick button head bolts will eventually by swapped in place along with a shifter boot and trim plate. The plastic anti-abrasion sheet is temporarily in place until the cover plate is finished. It creates the illusion that the cover plate is bent.


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