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ZL Auto to Manual Conversion What's needed! 

 

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 Post subject: ZL Auto to Manual Conversion What's needed!
Posted: Fri Apr 21, 2006 7:28 pm 
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I've owned my ZL for 10 yrs and rebuilt the standard auto twice, but now I'm wanting to convert to manual.

Can people out there that have done this point me in the right direction.

What do I need, and how do I go about it?

 

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Posted: Sat Apr 22, 2006 7:43 pm 
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all you need is the box(assuming your using a single rail), bellhousing, flywheel, clutch assembly, clutch cable, pedals, tube that mounts to the firewall where the clutch cable goes through( have a look on a manual xf, youll see what i mean). the output shaft between the auto and manual maybe different, i cant remember. another thing that makes it easy is the reverse light harnessthat comes with the manual, saves alot of messing around. one last thing is the centre console because the hole is different where the shifter comes through. anymore questions, feel free to ask, i only did the wifes zl about 3 mounths ago. to make things super easy, see if you can get your hands on a xf wagon as the floor is exzactly the same and you can use all the parts of it, including the tailshaft.
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Posted: Sat Apr 22, 2006 9:26 pm 
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Thanks for that advice, I'll start looking for a wagon xf - can you tell me did they come in the 5 speed?

Do you have any picks of your project with the ZL that might be helpful?

Sounds like a fairly easy job .... Looks to the god's .. yep think I can do this without to much pain...

Off to the wreckers this week to find a xf wagon... anyone got a wrecked one sitting around?

 

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Posted: Mon Apr 24, 2006 9:12 pm 
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did come in 5 speed, rare but. havent got pics as is a straight forward project for myself, completed in a day(joy of being a mechanic). if needed, i can give you a list of tooling needed and steps required to carry out said conversion.
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Posted: Mon Apr 24, 2006 9:28 pm 
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Thanks xdv8 I'm pretty handy with tools but a guide would be very helpful... esp. known little problem areas in the conversion .... what sort of box do you recommend if I'm unable to find one out of an XF given that they are apparently pretty rare?

 

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Posted: Mon Apr 24, 2006 11:22 pm 
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iirc auto and manual tailshafts are the same

 

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Posted: Tue Apr 25, 2006 12:00 am 
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Interceptor wrote:
iirc auto and manual tailshafts are the same


yep , tailshafts are the same.

late 87 xf's had 5 speeds in them . but make sure you get one from a 4.1 not a 3.3 as the 4.1 had the t5 and the 3.3 a light duty borg warner.

also if your ZL is unleaded you will need the kit from a unleaded car as the clutch cable runs down the lh side to clear the cat. converter
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Posted: Tue Apr 25, 2006 5:04 pm 
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more worried about lenght for the longer wheelbase
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Posted: Tue Apr 25, 2006 11:32 pm 
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Gday mate i have got a 5 speed comversion for a xf/zl it is complete with box flywheel clutch pedal box s**t clutch cable. I am after $550 for it..Please give me a call if you are interested in it. 0408506834. Brad
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Posted: Tue Apr 25, 2006 11:50 pm 
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uts and panelvans had the same wheelbase too

 

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Posted: Sat Jun 02, 2007 4:53 pm 
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Thanks for the offer bradels I'd already picked up a conversion for $600 which I've now fitted into the ZL.

Anyway it went very smoothly and only took about 5 hours with a mate. He knew a neat trick for getting the pedal boxes changed over. Just need to find a manual centre console and fit it.

 

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Posted: Sat Jun 02, 2007 10:15 pm 
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i seen a zl laney with a 289 up front, and a toploader (i think it was anyhow - long time ago)
the guy just cut a lil extra outa the center console... looks dodgy, but does the trick till you can get hold of a console to fit it all nicely / mod another zl laney console to look like it was ment to be manual...

 

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Posted: Mon Jun 04, 2007 9:27 am 
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xr8 dismantler wrote:
late 87 xf's had 5 speeds in them . but make sure you get one from a 4.1 not a 3.3 as the 4.1 had the t5 and the 3.3 a light duty borg warner.


T5's were also just a option until they finished XF's in 88, I know that is a fact due to Dad's best friend bought a carby 88 Falcon S sedan 4sp manual new straight after EA was release, and the fact I have replaced the rear main.

If you get the shifter boot you can cut out the centre console hole to suit, there is actually marks to show you where to cut, as the auto console hole is just narrower, a mate once did it using a aftermarket boot, it came out looking really tidy.

 

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