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  #101  
Old 28-03-2019, 06:21 AM
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I think you’re right with that wrap insulation. It doesn’t seem to actually reduce the radiated temperature, just slows down the transfer.

On my Duramax, we ceramic coated the dump pipe and first segment back to the end of the passenger foot well. That seems to work really well.
The previous Duramax done in the same workshop used that wrap insulation. It melted a plastic bottle on the passenger floor.
In mine, we’ve never noticed any additional heat in the passenger foot well.
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  #102  
Old 28-03-2019, 07:56 AM
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Set the new TC locking profile today. Lock start at 35km @1550rpm 2nd Gear, 3rd gear at 49km @1550 RPM 4th Gear @85km, @1600 RPM. to allow the car has more drive-ability, and the engine operating at the sweet range ( 1500 to 1950 RPM). The TC lock engage at 5% and disengaged at 45% of TPS to protect the transmission. During the normal drive, you never see TPS at 45%@110k hwy speed, the car will cruise @1725 RPM on 4th, or at the 3rd gear towing big caravan at 90k, RPM2042. I will get the heat shield done near the ATF sump and do a test. I really like this skiftkits.com.au TCU! stay tuned.
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File Type: jpg Shift TC Lock 28Mar 2019.jpg (55.4 KB, 25 views)
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT

Last edited by patrol97; 28-03-2019 at 08:38 AM.
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  #103  
Old 28-03-2019, 06:38 PM
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I have some test drive, is there a way to upload it here? Don't really want to use YouTube....

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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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  #104  
Old 28-03-2019, 08:11 PM
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After dinner did another fine tune for the shift point on each gear, line pressure, also the TC lock setting. Now can launch the Patrol like a sport car. Jamie from Shiftkits.com.au offered great help in tuning the Auto RE4.
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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  #105  
Old 29-03-2019, 08:57 AM
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Great work.
Great project.
Thanks for sharing.

Would love to see a video.
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  #106  
Old 29-03-2019, 05:02 PM
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managed to upload few videos:
https://www.youtube.com/watch?v=vhmd...ature=youtu.be

https://www.youtube.com/watch?v=VHnX...ature=youtu.be
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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  #107  
Old 29-03-2019, 06:30 PM
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the following video was the first start of the Cummins 4.5. on 31 Jan 2019. Due to air in the rail system, the first time start took long crank.....but it was one of the most important milestone for me: I can make it work!

https://youtu.be/RwK4n6llcEY
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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  #108  
Old 29-03-2019, 10:05 PM
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the factory standard TC works surprisingly well with the Stage 3 valve body, and the shiftkits TCU. The programmable TCU allowed me to find tune the line pressure value and each shifting, locking points. with the engine willing to rev, the car just feel easy and flexible to drive. The only areas need to be taken care of is to change ATF more often. better to add on another cooler. i was thinking about low stall TC as an option, but based on the performance of the factory TC, i delete the low stall TC option.
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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  #109  
Old 30-03-2019, 11:39 AM
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Love it!

What size tyres are you running? Reason I ask is regarding the diff ratio’s. Wondering what ratio I would need with a manual and either 33’s or 35’s.

Cause the manual normally runs a smaller ratio than the auto, can you even get lower than 3.5’s?


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  #110  
Old 30-03-2019, 11:55 AM
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I am on 275 70 R17 which is 32, if you are using 33 to 35, then the best diff ratio is 3.54. Cummins like 1500 to 2000 rpm range

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  #111  
Old 30-03-2019, 01:48 PM
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update: have done a test drive in the same road which i used yesterday. WOW, what an improvement after the ATF radiator cooling reconnected!. the ATF temperature dropped average 13 degrees compared to the yesterday. and the ATF temperature is also much more stabled compared without the radiator connection. the highest reading from the outlet is 95 compared yesterday's 108, and the highest internal temperature reading ( from the TCU logfile) is 75 degrees compared to the yesterday's internal reading 90 degrees. I strongly suggest everyone to reconnect your ATF cooling line to go through the radiator.
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  #112  
Old 31-03-2019, 01:47 PM
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Just did a Sydney to Newcastle freeway run, at 110km/h , engine rpm 1780, egt 245, very relaxing a d quiet. No problem with any hill sections.

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  #113  
Old 31-03-2019, 05:46 PM
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Fuel economy update, the first 430km trip with about 20% local road and 80% freeway from the Sydney to Newcastle used 10.8litres/100km fuel. This is pretty good for a new Diesel engine which has not been run in yet. Cummins engineer told me the engine will need 5000km to run in. Light load, 2 people on board. Also, withe ATF now going through the heat exchanger at the bottom of the radiator, the ATF temperature during the trip is very stable.
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  #114  
Old 31-03-2019, 06:05 PM
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On the way to Newcastle, i had the TC lock setting at max 48%, but on some incline, the TC will unlock a bit too earlier. Before heading back to Sydney, i changed the TC unlock to max 53% on the TCU setting which see the Auto Transmission rungs much better, most time the TC is stay locked except some step incline. FYI, due to the massive torque from Cummins, i dont want to set the unlock too high, since disk inside the TC is only small. i changed the setting based on my previous remapped ZD30 experience on the same section of the road. I would agree, in this kind of incline, a manual box would shine!
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  #115  
Old 31-03-2019, 06:20 PM
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one thing i need help from some expert here. my speedo is out : @100, it shows 92. i had installed 15teeth speedo gear, for my model, the 14teeth gear cannot be installed. However, i have a shiftkits TCU which has correct speed output line. I will need to connect this line to the speedo input on the dash. i knew that if i remove the dash, i could do join the wire there. but I prefer to join it somewhere easier. i have to make sure do not cut the speedo signal feeding to the TCU, where else i can find the join point?
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  #116  
Old 01-04-2019, 06:24 PM
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on the weight bridge today, total weight 2.74T, front 1.5 rear 1.24. With the steel bullbar (no winch), and new 4.5 Cummins engine, it gained a bit weight. Looks like the new engine is about 70kg heavier than the zd30. how is everyone else's patrol's weight?
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2006 ST GUIV to Cummins ISDE4.5 DIESEL, RE4 AUTO, EGT, FRONT IC, 2" left, ARB Bullbar, CUMMINS Engine Monitor, 3.54 DIFF, Stage 3 HD Valve body, Shiftkits Programmable TCU, BF LT275/70/R17AT
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  #117  
Old 01-04-2019, 10:08 PM
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update for speedo correction: i cut both wires off from the speedo pinion gear output cable, and joined the TCU's speedo output signal to that 2 wires, wow, it is as accurate as the GPS speed.
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  #118  
Old 02-04-2019, 10:02 AM
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Cut the 2 wires, then join them to the TCU output, setting up TCU tachout, to adjust VSSout unit to increase or reduce the speed on dash to get very accurate reading

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  #119  
Old 02-04-2019, 08:24 PM
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The ATF cooler arrived. Measured 289x210x38. I will paint the support brackets, then install it in the front of IC. This is the 3rd cooler, hopefully the ATF temperature can go back to zd30 time.....

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  #120  
Old 03-04-2019, 01:17 PM
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Using the winch mount 4 holes to install and secure the ATF cooler. Very easy access and enough gap between the IC and the transmission cooler. The cooler hold about 450 ml ATF.

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