Auto to Manual swap

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kiwi
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Auto to Manual swap

Post by kiwi »

Got this crazy idea to use the TZS gearbox and clutch plus all the other gubings on the TZS Auto!

Why because I have a susp the gearbox is not long for this world and the Manual is in good nick.

Anyone done this swap and what problems did you encounter?
1991 BX19 TZS 04/01/91 (Deceased)
1990 BX19 TRS 27/10/89 (Reborn)
1992 BX19 TXD (Ex UK - K 744 SDF) 15/06/92
1990 BX19 TZS Auto 06/11/1989
1992 BX TZD Turbo Estate (Ex UK) 1/07/91
Dollywobbler
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Re: Auto to Manual swap

Post by Dollywobbler »

Have a search on this forum. It's been done before for sure.
citronut
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Re: Auto to Manual swap

Post by citronut »

i did one a few years back and it was not much more difficult that doing a clutch and pedal box really

regards malcolm
curent ride
K reg BX 17TD TZD est
also own
K reg D special

no longer have
H reg CX saffari 2.5 TRI (now gone to Malaysia)
R reg xantia 1.9TD est (gone to meet its maker)
kiwi
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Re: Auto to Manual swap

Post by kiwi »

Really dumb question about to be said.

When I (if) do the swap can I use the same good clutch or would I need to get a new one?
1991 BX19 TZS 04/01/91 (Deceased)
1990 BX19 TRS 27/10/89 (Reborn)
1992 BX19 TXD (Ex UK - K 744 SDF) 15/06/92
1990 BX19 TZS Auto 06/11/1989
1992 BX TZD Turbo Estate (Ex UK) 1/07/91
citronut
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Re: Auto to Manual swap

Post by citronut »

kiwi wrote:Really dumb question about to be said.

When I (if) do the swap can I use the same good clutch or would I need to get a new one?

:rofl: :rofl: :rofl: :rofl:
curent ride
K reg BX 17TD TZD est
also own
K reg D special

no longer have
H reg CX saffari 2.5 TRI (now gone to Malaysia)
R reg xantia 1.9TD est (gone to meet its maker)
rutter123
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Re: Auto to Manual swap

Post by rutter123 »

i have recently done this on my tgd the auto box was dead and i changed it to manual quite simple to do, you will need a flywheel, flywheel bolts (as manual ones are longer) clutch kit, pedal box, clutch cable, gearstick and all the linkages including the ball pivot that sits on the top of the steering rack, new driveshaft seals, clutch plate inspection cover, hydraulic pump bracket, you will also need to rewire a few electricals such as reverse lamps and auto gearbox lockout switch, this was the case for a 1.9n/a diesel the driveshafts are same auto/manual, all fairly straightforward and just spannering, would advise the pedal box and clutch cable can be a bit fiddly, its prob easier to remove the complete eng/box together if u have the equipment, this also makes it a lot easier to fit and line up the pedal box and clutch cable. have done about 6000 miles in mine since converting with no issues just had to re adjust the clutch after 100 miles or so. and yes a new clutch false economy not to but thats your call.
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kiwi
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Re: Auto to Manual swap

Post by kiwi »

citronut wrote:
:rofl: :rofl: :rofl: :rofl:
[-X yea I said dumb question just working out the cost effectiveness of the idea.


The idea of removing the engine gearbox together is not an option. Couple of reasons both cars are 19TZS and both have Aircon fitted so remving the engine would result in added cost of the aircon regassing. Second reason is the Engine on the donor is stuffed or pretty close to being stuffed so would be a false economy.

So yes I have an entire car full of usuable gearbox parts to transfer over so by the sounds of it its just basically a Clutch replacement. Reason for the dumb question was would I get awy with using the donor cars clutch even if it dont last long.
1991 BX19 TZS 04/01/91 (Deceased)
1990 BX19 TRS 27/10/89 (Reborn)
1992 BX19 TXD (Ex UK - K 744 SDF) 15/06/92
1990 BX19 TZS Auto 06/11/1989
1992 BX TZD Turbo Estate (Ex UK) 1/07/91
citronut
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Re: Auto to Manual swap

Post by citronut »

aaaah i see i thought yoou ment re/use the clutch from the Auto :twisted: :D :wink:

depends how much life the clutch from the manual car has left, otherwise that would be false economy,

regards malcolm
curent ride
K reg BX 17TD TZD est
also own
K reg D special

no longer have
H reg CX saffari 2.5 TRI (now gone to Malaysia)
R reg xantia 1.9TD est (gone to meet its maker)
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MULLEY
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1991 Gti 16V - Blaze - crash damaged, will get repaired - SORN
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1988 CX 25 GTI Turbo2 - SORN
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Re: Auto to Manual swap

Post by MULLEY »

Don't be tight, fit a nice shiny new one ;) There would be nothing worse than having to fit a new clutch only a couple of years down the road, so it makes sense to fit a new one. Out of interest, how can you tell how much wear an old clutch has had & how long it will last?
2002 C5 2.0 HDI Estate - Jasmine - Now SORN
2011 Mini Cooper D Clubman - SOLD
2016 Mercedes A180D Sport - Auto refinement
1992 TZD Turbo - Bluebell - My daily
1991 Gti 16V - Blaze - crash damaged, will get repaired.
1990 Gti 8Valve SOLD - looks like it's been scrapped
2002 Mini Cooper S - SOLD - i miss this car
1992 TXD - Scrapped in March 2014
1988 CX 25 GTI Turbo2 - SORN
1996 - AX Memphis 1.5D - Dream - SORN

I'm not just a username, i'm also called Matthew.
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mat_fenwick
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Re: Auto to Manual swap

Post by mat_fenwick »

kiwi wrote:both have Aircon fitted so remving the engine would result in added cost of the aircon regassing.
Just unbolt the compressor and support it out of the way, that is if you wished to remove the engine too.
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1993 1.9 TZD Turbo Estate
1996 3.9 V8 Discovery
1993 VW LT35 campervan
1985 Hyundai Stellar V8
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bx_pallas
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Re: Auto to Manual swap

Post by bx_pallas »

New clutch, release bearing and crankshaft seal is a must! :) (new clutch calble is also advisable)

Access to Steering and brake valve is also a lot easier when there is space!
rutter123
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Re: Auto to Manual swap

Post by rutter123 »

the haynes manual will give u some guidance as to wear limits on the clutch plate, , but bear in mind sometimes the pressure plate can be at fault which is usually the case with recon clutch kits, (they are rubbish dont buy one) many types of clutch available on ebay here from about £20 upwards some NOS, as i got for the tgd NOS valeo £30 not sure about your spares availability in nz tho. as mulley says a nice shiny new one would be the way to go, you only wanna do the job once, dont you? i used a suitable piece of timber or bar across the slam panel and bulk head, fix a ratchet strap to this and the other end of ratchet strap to the lifting eye on top the gearbox will assist with lifting the box from the floor into place unless you have other help, you will also need to bypass the water cooling unit on the auto box or just join the hoses together, removal of the radiator does help as you can then push the flow dist valve out the way and makes it a lot easier to get the gearbox in.
90 BX Tzd turbo 294k SORN undergoing major surgery
90 BX Tzd turbo estate 46k awaiting surgery
65 Peugeot Boxer Van the new workhorse
52 Toyota Rav4 180k Bulletproof Jap reliability
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mat_fenwick
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Re: Auto to Manual swap

Post by mat_fenwick »

bx_pallas wrote:Access to Steering and brake valve is also a lot easier when there is space!
True, but taking the gearbox out won't help on a RHD car :wink:
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1993 1.9 TZD Turbo Estate
1996 3.9 V8 Discovery
1993 VW LT35 campervan
1985 Hyundai Stellar V8
2016 Hyundai iLoad
bx_pallas
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Re: Auto to Manual swap

Post by bx_pallas »

mat_fenwick wrote:True, but taking the gearbox out won't help on a RHD car :wink:
Haha! I totally forgot you dont have any padals there! :D But don't they have LHD BXs in New Zealand anyways?

Take one RHD clutch cable and you can make three LHD ones out of it! :D
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