auto to manual conversion TD5

Mpower! · Dec 13, 2011

after just sitting in the back of an AA lorry for 9 hours and my 3rd auto box blowing on me at the end of the wayfarer byway in wales im converting over to a manual. i know this is going to be a biggish job and an exspensive one but the auto box isnt any good for off road.

im after anyones help/knowledge on this. im going to start a list of kit i need get it orderded and then hopefully work my way through it.

so far i can workout from searching the net.

Manual gearbox
brake and clutch pedal assembly
clutch and flywheel
manual gear knob and linkage to top of the box
clutch slave cylinder
clutch master cylinder
a new ecu? (or can the auto one be re-programmed?)
also think i read of some sort of linkage from transfer box to gearbox?
and apparently i can keep the same props?

anything else?

Thanks again

jamesmartin · Dec 13, 2011

id talk to alive tuning about electronic part ,reservoir for master cylinder is share with brakes and should be a little blocked off pipe to take feed from just cut off bottom bit ,you can either buy cable and lever kit for diff lock or use 300 tdi gear box top and lever/linkage assembly if you speak to dan at amazon 4x4 he should be able to sort most of bits out (01673863322)

Mpower! · Dec 13, 2011

jamesmartin said:
id talk to alive tuning about electronic part ,reservoir for master cylinder is share with brakes and should be a little blocked off pipe to take feed from just cut off bottom bit ,you can either buy cable and lever kit for diff lock or use 300 tdi gear box top and lever/linkage assembly if you speak to dan at amazon 4x4 he should be able to sort most of bits out (01673863322)

ok so everything ive got on my list is needed? ive already got the centre diff cable already (if thats what you meant). ok ill ring him in the morning!

is the pedal assembly just abolt in job or am i going to have to cut out the bulkhead between the interior and engine bay for cables/pipes?

pedros · Dec 13, 2011

Mpower, would it not be easier just to sell the auto and buy a manual? I don't know about financially, but surely a consideration?

jamesmartin · Dec 13, 2011

just a hole for master cylinder , dont forget cooler pipes etc with gearbox and if you get one from someone like dan get lever ,gaiters etc,is easier to get the bits from someone that breaks them than as individual bits

Mpower! · Dec 14, 2011

ok sounds good but im planning on getting a new gearbox and transfer case from ashcroft. if i order manual parts it should have the right linkages? possibly?

also do you know where i can find images like the landrover dealers use to find parts? just to get a rough guide of how it goes together and where the hole goes.

\Thanks again.

listerdiesel · Dec 14, 2011

The bulkhead should already have holes for both auto and manual versions. As far as I know, there is no special variant for auto compared with manual.

Microcat is the dealer parts system, if you let me know what images you need, I'll screendump them out tonight.

There is no ECU for the manual box.

The BCU will need re-programming for the manual transmission.

Centre console is different, as is the rubber mat that sits on it.

Peter

Mpower! · Dec 14, 2011

listerdiesel said:
The bulkhead should already have holes for both auto and manual versions. As far as I know, there is no special variant for auto compared with manual.

Microcat is the dealer parts system, if you let me know what images you need, I'll screendump them out tonight.

There is no ECU for the manual box.

The BCU will need re-programming for the manual transmission.

Centre console is different, as is the rubber mat that sits on it.

Peter

ok excellent if you could get me the brake pedal assembly picture and the centre console and gear lever pictute with part no.s would be a great help.

paulw · Dec 14, 2011

I know it's not the same but i did this on a mark 4 cortina many years ago and the auto box had a switch on to disable the starter motor when in either drive or reverse, starter will only operate when in manual or park, i kept it as a security device so you had to press the switch manually before starter would operate, don't know if it's the same on landys but someone will let you know

xat44 · Dec 14, 2011

is on my d2

Mpower! · Dec 15, 2011

all parts have been ordered and is booked in on the 11th january to have the conversion.

i also went for a new t/c with the defender 1.4 ratio in and a heavy duty cross pin, hopefully will help with stuff.

just cant find a part number for the clutch hose. and the cover plate and foam matting. anyone help with this?

listerdiesel · Dec 15, 2011

Not quite as simple as that, the inner workings of Rover's parts system are weird and wonderful.

Here are the three areas you asked about.

TD5 and V8 pedal boxes are different.

Peter

Mpower! · Dec 17, 2011

ok cheers mate. where do i get that software your using looks like it could come in handy?

gil · Dec 17, 2011

http://www.landroverresource.com/docs/D2_Workshop_Manual.pdf

Mpower! · Dec 19, 2011

ok thanks so far guys.

i now have the following parts.

Manual gearbox
Transfer box with 1.4 ratio
clutch
flywheel
master clutch cylinder
slave cylinder
manual pedal box
clucth fork
clutch bearing
flywheel bolts
gear linkage.
clucth hose

is there anything else people can think of?

the other thing i need is a gear knob which im still searching for.

thanks again.

sierrafery · Dec 19, 2011

A clutch switch on the hydraulic circuit which has to be wired into the ECM...otherwise u'll miss the so called "surge damping" >

"The switch is operated by hydraulic pressure when the clutch pedal is pressed. The ECM uses the signal from the clutch switch for the following functions:
l To cancel cruise control if operating.
l To provide surge damping during gear change.
Surge damping stops engine speed rising dramatically (engine flaring) during gear change. Surge damping assists driveability as follows:
l Smoother gear change.
l Greater exhaust gas emission control.
l Improved fuel consumption."

Mpower! · Dec 19, 2011

ok do you have a part number for this? and where did you get your info for that from so i can have a read up on that, thanks

just had a look and it looks to be more of a plug than a switch i think? im assuming ive got to get hold of the plug/switch and somehow solder it into the ecm?

sierrafery · Dec 19, 2011

U need the whole assy nr.10 > http://www.landroverclassicparts.com.au/ProductDetailLarge.aspx?largerProduct=109365

Info about it in RAVE > engine management > description> clutch switch (18-1-27)

IMO the plug for it might be there somewhere near the fusebox in the engine bay cos there is that switch on mine

Mpower! · Dec 20, 2011

Anyone know where I can get a clutch switch? There an obsolete item now. Dealer can't get hold of one and my local breakers don't have anything.???

sierrafery · Dec 20, 2011

Take it by parts > MSK100070 + STU100270 + SZS100040 ...u'll find these separately or search with "....diesel controll switch assy"

auto to manual conversion TD5

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