240ZF

 

1972 DATSUN 240Z

S/N HLS30-99527

 

(Updated 08-31-09)

 

 

          Prior to disassembly:

 

                   1        2        3        4

 

          Disassembly:

 

                   1        2        3        4

 

          Parts from parts car (1973 model):

 

                   1        2        3

 

          Body repair (the guy in some of the pictures is Mike Arne who helped with the body work):

 

                   1        2        3        4        5        6        7        8        9        10

 

                   11      12      13      14      15      16      17      18      19      20

 

                   21      22      23      24      25      26      27      28      29      30

 

                   31      32      33      34      35      36      37      38      39      40

 

                   41      42

 

Restoring parts:

 

                   1        2        3        4        5        6        7

 

          Transmission (F4W71B):

 

                   1        2        3        4        5        6        7        8        9        10

 

                   11      12      13

 

          Engine (L24):

 

                   1        2        3        4        5        6        7        8        9        10

 

                   11      12      13      14      15      16      17      18      19      20

 

Assembly:

 

          1        2        3        4        5

 

                   (Engine installation)

 

          6        7        8        9        10      11      12      13     

 

          14      15      16      17      18      19      20      21      22      23

 

 

          5-27-07:    24       25      26      27      28

 

 

8-12-07     Finished!

 

1        2        3        4        5        6        7        8        9

 

11      12      13      14

 

 

10-30-07     Decided to install adjustable coil-over suspension (Ground Control Systems)

 

1        2        3        4        5        6        7

 

 

4-13-08       Added Mallory electric fuel pump and filter

 

1        2

 

6-29-08                 Added Stainless louvers to the hood, aluminum rear hatch louvers, and BRE type front spoiler

 

1        2        3        4        5        6        7        8        9        10

 

1-09            The 240SX transmission swap

 

8-09  3.90:1 R200 differential and 300ZXT CV half shafts installed

 

 I got an open 3.90 R200, the R200 mustache bar, and a set of rebuilt 300ZXT CV half-shafts. I designed my own stub axle conversion flanges to minimize the length. I ended up with a design that is about 1/8"-1/4" shorter per side (a guess looking at the pictures) than the ones from Modern Motorsports (and cost me less than $100/pair to have made at the local machine shop). I’ve had it up to over 100 mph with no noises or vibration.

 

My adapter flanges: I started with an oversize circular 3/8” thick mild steel plate and milled a rectangle out of the center to be a precise interference fit with the outside of the original flange and to a depth of the original flange (about .230” deep). Next, the plate was heated so the old flange could be inserted. After the plate cooled, shrink fitting tight onto the old flange, they were welded on the back side. Next the assembly was chucked up in a lathe and turned down to the diameter of the CV flange ears and a thickness of about .330”. Finally, the center was machined out to accept the raised alignment ring on the CV housing to a depth of about .100” and the matching bolt holes were drilled. This puts the alignment ring and CV end cap almost in contact with the mating surface of the original flange.

 

1        2


After tightening the stub axle nuts, I cut/ground down the ends of the stub axles so they only protruded about 1/16” through the nuts. This was necessary to keep the CV end plate from hitting the ends of the stub axles when installed.

3

The R200 and 300ZXT half-shafts:

4

The R180 with the front mount still on it in the stock orientation:

5

The R200 installed with the front mount in the stock orientation:

6


The installed CV half-shafts:

7        8

 

The stock R180 limiter strap installed in the stock position over the R200:

9


heimsothtn@comcast.net