ZF Gearing calculator/in-depth photos

Hi guys,

As a certified (certifiable?) Pantera Dork, I have been kicking around with ZF gearboxes for almost 20 years. One of the best online resources for Pantera guys is a website run by a fellow named Mike Dailey in Atlanta, www.panteraplace.com

In the technical information section, he has a couple of pages that are dedicated to the ZF. This one is very interesting, for it shows in-depth photos of the gearbox during each stage of assembly:

http://www.PanteraPlace.com/page151.htm

On this page, he has a downloadable Excel spreadsheet which is really quite brilliant.

http://www.PanteraPlace.com/page32.htm

Don't waste your time reading the poorly reproduced magazine articles; instead just click on the link for the downloadable Excel file.

It assumes 'standard' ZF gear ratios, with a 4.22 ring and pinion, and a 26.5 inch tall tire (BFG says their 295/50-15 is 26.7 inches tall, so that's a good starting point). The spreadsheet allows you to change any number of variables, including tire diameter, each gear ratio, and the ring and pinion ratio. It is actually set up to display data for a ZF six-speed; the first five gear ratios displayed are the standard ratios for the standard five-speed.

The only flaw in this spreadsheet is in its presentation; the column headings don't line up properly with the data, so the data for 1st gear, for example, is displaced to the right, almost under the heading for 2nd gear. To correct this, I downloaded the read-only file, then did a save-as with a new filename. This new file I could then manipulate, and I highlighted the 'results' cells and changed them to 'centered'.

Once properly formatted for human viewing, the results are quite illustrative. Lloyd Butfoy told me that unless otherwise ordered, the new gearboxes that he is quasi-mass-producing are fitted with 3.77 ring and pinions, which is different from the 'standard' 4.22 ratio fitted to Panteras and (most) Mangustas. Although that is great for top-speed bragging purposes (assuming a 26.5 inch tire, 6500 rpm equates to 193 mph), it has been my experience driving 3.77-equipped Panteras that the taller rear end ratio really blunts acceleration.

While admittedly the GT40 received 3.77 gears when running at the high-speed tracks like Le Mans, a host of different ratios were available, and on the short tracks gearboxes with as low as 5.25 were sometimes fitted.

Even with the 4.22 gearing, most race tracks in the USA are so tight that you will rarely (if ever) get into 5th gear; a 3.77 virtually guarantees that you will spend almost all your time in 2nd and 3rd gear, getting pulled coming out of the corners by cars that arguably should be slower than yours.

The one advantage of the 3.77 for street use is that it provides more relaxed freeway cruising. But consider that 4th and 5th gear are unusually close together; at most speeds there is only about a 500 rpm drop shifting from 4th to 5th.

It seems to me that if low rpm freeway cruising combined with electrifying back roads and racetrack performance is the goal, the ideal combination would therefore be a 4.22 ring and pinion coupled with a taller 5th gear. Lloyd sells both .655 and .642 5th gears to replace the stock .705 ratio; the .642 ratio gives about a 1000 rpm drop when shifting from 4th to fifth at freeway speeds.

The spreadsheet shows a gearbox so-equipped would deliver 144 mph in 4th gear at 6500 rpm, which is about all you could expect on an American track, yet 5th gear would allow a top speed of 189 mph at the same rpm. More importantly, it would allow you to cruise at a mere 2500 mph at 70-ish (actually 73) mph.

This presumes that relaxed cruising is your ambition, which is far from universally true. Personally I would just stick with the standard gearing.

In any case, before plunking down your hard-earned cash on a gearbox that is available with a variety of different options, you owe it to yourself to spend a few minutes honestly assessing how you intend to drive the car, and then fooling around with this spreadsheet to ensure that the gearbox delivers what you want it to.

And remember this--there will be virtually no opportunity to actually drive the car at 200 mph anywhere in the USA. But you can cheerfully lie about it at the car show and tell people that it’s a 200 mph car, then blow their doors off with the acceleration that your lower gearing affords you. :)
 
Is it an easy job to change the ring and pinion, so that we can change from a 3.77 to 4.6 or 5.37 which would then give a choice of top speed or acceleration.
alistair
 
I forgot to mention that the page that shows the various disassembled views of the ZF is philosophically geared (agh!) towards the Pantera, meaning that the gearbox is depicted in its Pantera orientation (which, technically, is 'upside down' from its original design orientation).

So, in the photos that depict it 'right side up' and 'inverted', realize that in the GT40 those roles would be reversed.

With respect to changing the gear ratio, it is a fairly complex process. If you are proposing owning several gearsets and changing back and forth with a single gearbox, you can forget about it. Racers who want to change gear ratios do so by swapping gearboxes back and forth. It's really not practical to do it any other way.
 
Mike-
I have a ZF box from an unknown donor car. I suspect it might have been a Lotus 30 or a F5000 since that’s what the development guys had in the shop when they made the switch, but all I’m sure of is that it ended up in my Lotus 47GT. I've enclosed a pic of the ID plate in the box. Could you speculate on what the original car’s identity might have been and the sort of race course it was geared for?
Your spreadsheet is terrific although when I plugged in the box’s numbers and 21.5 “ for the 13” wheels/tires on the car, I was a little disappointed to see a top speed at 6500 RPM of only 131 MPH. But then, with 450 HP in an 1800 lb. car, it’ll get there real fast!
John
 

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toy264 said:
Mike-
I have a ZF box from an unknown donor car. I suspect it might have been a Lotus 30 or a F5000 since that’s what the development guys had in the shop when they made the switch, but all I’m sure of is that it ended up in my Lotus 47GT. I've enclosed a pic of the ID plate in the box. Could you speculate on what the original car’s identity might have been and the sort of race course it was geared for?

It appears from the dataplate that you have a 5 DS-25 gearbox (as opposed to a -1 or -2 which are much more common). The original 5 DS-25 is philosophically similar to the later versions, but there is practically zero parts interchange between them, making the first-generation (sometimes called the -0 even though ZF never referred to them that way) gearboxes considerably more expensive to repair.

A fellow Pantera buddy recently wrote to me about a ZF -0 differential that is on E-bay right now, and he wrote:
===
ZF transaxles came with two completely different kinds of limited slips: the
clutch-type that are in maybe 98% of all Panteras, and a sprag-type unit found
in the GT-40s, some Mangustas and a very few
early street Panteras. The sprag unit was popular at one time for
long-distance racing since it put far less heat into the lube due to clutch-plate
slippage than the later ones, but it also needed rebuilding more frequently- and
Lloyd Butfoy is about the only place on the planet you could go to get one
serviced.
===

With respect to the source (donor car) for your gearbox, I have no idea. I don't know anything about the Lotus 47; could it have been an original installation? In any case, the gearing is clearly set up for short course work. In fact, your 5th gear ratio is exactly the same as 4th gear in a 'normal' Dash-2 gearbox.

ZF published service manuals (highly in-depth) for these gearboxes; the Pantera Club has reproduced the manuals for the -0 and -2 (what happened to the -1???) in a single volume. If you are contemplating any serious ZF work, or even if you are mildly curious as to how your transaxle works, you can order the book from the club store. Go to www.panteraclub.com and click on the 'club store' button, then go from there.

According to the manual, there were not all that many gearing options available for the -2, whereas there were tons of options for the -0 (both in terms of individual gear ratios, and final drive ratios). I happen to know that the -1 had many more variations than the -2, perhaps as many as the -0.

toy264 said:
Your spreadsheet is terrific although when I plugged in the box’s numbers and 21.5” for the 13” wheels/tires on the car, I was a little disappointed to see a top speed at 6500 RPM of only 131 MPH. But then, with 450 HP in an 1800 lb. car, it’ll get there real fast!
John

No doubt about it! Your gearbox is clearly set up for sprint work.

BTW, if you need any work done to your gearbox, since you live in Houston you might want to ping John Taphorn, who is a member of the Space City Pantera Club, and the president of the Pantera Owner's Club of America. He has rebuilt several ZF gearboxes using some home-made tools and jigs, both for Panteras and for local race cars. His contact info can be found on the club's website referenced above.

As a final note, the ZF manual shows each of the custom tools that ZF produced for specialists who would work on these gearboxes. Back in 1993 I interviewed Dennis Quella; he has the complete tool kit (it consists of about 20 individual tools and jigs). He inherited it from his father, who was a ZF specialist for race teams back in the '60s; Dennis told me that the kit was still available new from ZF, for the paltry sum of $90,000!!!!!!! Lord knows what it would cost today?

So, that is another reason why only a handful of people in this country spend a lot of time working on these gearboxes. John Taphorn has been able to make do by copying some of the tools and jigs (I think he got the patterns from Lloyd), and developing work-arounds for the rest.
 
Mike-
Thanks for your detailed answer. I'll get in touch with John Taphorn when I get close to finishing the drivetrain if he works on the -0, otherwise, is Mr. Butfoy still doing the work? The magazine article on the particular 47 I own mentioned the box tended to pop out of third, so I've been setting a little aside to have it gone through at some point.
Should you be interested, here's my page with some details etc. on the 47, and again, thanks for the information. index.htm
John
 
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