Can some of you very talented zedders give me an idea of the best way of going about a auto to manwell conversion, including the bits n bobs I will need to purchase to do the job properly.

 

Do I need a diff ecu or propshaft etc

 

What are the pitfalls and what do I need to be looking out for probwise.

 

Cheers

 

Marc

http://www.z1motorsports.com/PDFs/Autoto5spconversion.pdf

You need:

Gearbox ;)

Clutch

Flywheel

Spacer plate thingy between box and engine.

New Release and Spigot bearings

Front section of manual prop.

Master cylinder (Later models had bleed nipple which is better)

Slave cylinder (I'd use new)

Clutch pedal and booster

Brake pedal

Clutch pipes from inner wing

Manual alternator/box harness

Vacuum tanks from inside drivers wing near AIV's

Balance bar from manual car

Vacuum pipes from balance bar to master cylinder.

 

I think thats about it really it's pretty straight forward but you need to solder a few wires on the harness to join it in and getting the pedal in is a real pain.

This was my list (from the FAQ section)

 

 

Gearbox

Gear lever

New leather gear lever boot + 2 rubber boots underneath

Master cylinder

Slave cylinder

All hydraulic pipework

Pedal box

Flywheel

Pressure plate

Clutch disc

Throw out bearing

Front half of the propshaft

The plate that sits between engine & gearbox

Wiring loom for the reverse & neutral gearbox switches

Wiring loom for the alternator

Both clutch servo vacumn tanks + pipework

 

I would also recommend replacing all the cheap rubber bits like dust seals and so on, plus the gear shift bush and the gearbox rear mount & prop centre bearing.

And bear in mind that nearly all the s/h manual boxes are now 15/16 years old and many will be thrashed to death in a previous car.

you've got a point there slick,

 

ive got a spare auto box but was considering the worth of going manwell.

 

Nice thing about autos is that when you gas it they dont let off like a manwell, they just keep on getting faster n faster, within the national speed limit of course ;) ....sometimes :eek:

 

My mate paul, rainbowztt, has a manual and it has a bit more appeal to me. Im just being careful cos I know what a money pit these cars can be :D

 

So far my cars been well looked after, only prob being the box that went while I was gassing it :confused:

 

I would prefer to do the job myself so I know exactly whats going back in the car, or at least be around while its being done so I get to know the inside of the car a bit more.

 

Are there any real pain in the @rse jobs involved in doing the conversion?

Or is it fairly straight forward....I'm not a spak when it comes to mechanics so I dont mind working on the car.

 

Marc

There's always me to help, we can both stand their and scratch our heads and go what the f**k have we started. I've done a fair bit of work on my motor so we should be able to work it out. :D

Might have to buy a car lift cos mines a bit low lol

 

Its gonna be fun what ever I do.

 

Im defo on the way down the Manwell route, just want to make sure I dont miss something lol

 

Cheers bud

One of the nasty bits is fitting the clutch pedal and hydraulics. Even knocking the blanking plate out from the bulkhead was not easy.The next barsteward job is removing the spigot bush from the flywheel/crankshaft as the automatic box uses a larger bush so it has to be changed. And just when you think you've cracked it, actually fitting the manual gearbox can be a PTA, and they are heavy. The first time we tried we had to put down again because it would not align and being a bug lump, fatigue set in. Second time tho', it was done. Make sure to got the bolts for the flywheel, clutch and off course pedal fitment. You have either got to change the brake pedal or slice it down to normal size. Have new pedal rubber ready to fit. Check gearlever bushings for wear, they are easier to replace before you fit the box then afterwards.

Hello bud,

 

Did you find it worth all the effort?

 

Time for me is limited and there is no one up here in the north of england who touches zeds :confused: So it looks like im gonna have to do it myself, with rainbowztt ;)

 

Im trying to gather as much info as I can before I set to n start messing with the car.

 

Cheers

 

Marc

I did mine myself and it was dead easy but I did have the engine out at the time :)

There's nothing difficult about it just the agony of lying on your back trying to get the clutch pedal bolts in under the dash LOL

iv done around 5 now

 

piddly bit is like old z has said is running the booster and pedal

 

also the standard pipework is fiddly to run down the bulk head, so a custom braided hose with male/male m10 1mm pitch connectors each end to fit slave-master cylinder is the best way forward, and am doing to same on my s14a at the moment ;)

 

as chris has said^ engine out is even easier :) but abelt drastic to do a manual conversion LOL

If you do decide to do this fella could you take some photo's throughout the change and put up a "how to" kinda thing? as i will be looking to do this and living in scotland there arent any places that would be able to do it, and like yourself id like to do it myself so i know more about the car!

 

Would probably be a great help to other people thinking about it as well :duffer:

Thats exactly What I was going to do bud :)

 

Get a comprehensive list and pics together of all the parts and then produce a step by step haynes type manual so other peeps could tackle the job at home etc.

 

I was up in Dundee a couple of years ago, I was a sponsor of the Dundee Guitar Festival :dance: Love the statues in the town :)

 

Drove all the way from Kent :wack:

Thats exactly What I was going to do bud :)

 

Get a comprehensive list and pics together of all the parts and then produce a step by step haynes type manual so other peeps could tackle the job at home etc.

 

I was up in Dundee a couple of years ago, I was a sponsor of the Dundee Guitar Festival :dance: Love the statues in the town :)

 

Drove all the way from Kent :wack:

 

Awsome mate.... sound like a mint plan :)

 

been in dundee for 2 years now, moved up from Odiham nr Basingstoke as im in the RAF... its a good night out!

Ive just completed a conversion myself and found it all pretty straigh forward. As previously mentioned, its a pain to remove the auto spiggot bush. After hours of hammering, i decided to drill it to weaken it then split it with a chisel - came out easy but be careful not to drill too far into the crankshaft.

 

Next main problem has been the propshaft. Try to get a full manual one to avoid splitting and coupling together your auto rear section with a manual front section. Mine has been vibrating since the conversion and is now away to get balanced despite trying rotating 90 degrees at a time to no avail. These cars seem to be prone to prop vibrating problems and its not easy to get to once put back together (exhaust, heat shields etc).

 

My final piece of advice is to ensure you get all of the parts required if bought as a kit. Despite paying good money, there were numerous parts missing from my "kit" which I have not managed to get hold of yet or have cost me a small fortune (gear knob, gaitor, clutch vacuum tanks, manual balance bar) to name but a few.

 

After all of this, not sure if I prefer manual but have not really had a good run in it yet due to prop problems.

 

Hope this helps.

You sure the vibration isn't the g'box rear mount or the prop centre bearing? Its worth replacing the rear mount while the box is out along with a new centre bearing IMO..

Rear mount and bearing were used from my auto box/prop which was perfect with no vibration at all so cant see them being the problem. Hopefully it will be resolved when I get the prop back balanced.

I'll Give You A Hand If Ya Need It I'm Only In Newton Aycliffe And I've Got Plenty Of Tools I've Seen You At Teesside Park A Couple Of Times But You Were,nt Around To Speak To Just Let Me Know Mate.