1983 Jaguar XJ-6 5 speed manual gearbox conversion

[novom2001]

The transformation is amazing, even in a car as well worn as mine. There were no instructions, and this was my first time to do this job. A friend had come across the adaptor plate to mate the tranny to the bell housing some time in the past, so I knew It could be done. From there, I just took it one step at a time. If you follow the link to my website,you will find a general idea of how I did it.

If you want to do it for your car, I will be happy to share with you what I know.

[TheRealKeiff]

Are there instructions that you followed or di know know how to do this through experience? i really want to do this to my 87 xj6 and would love to know how you did this!!! brilliant sir brilliant!!!

[novom2001]

@TheRealKeiff The transformation is amazing, even in a car as well worn as mine. There were no instructions, and this was my first time to do this job. A friend had come across the adaptor plate to mate the tranny to the bell housing some time in the past, so I knew It could be done. From there, I just took it one step at a time. If you follow the link to my website,you will find a general idea of how I did it.

I will be glad to share what I know if you decide to do it to yours.

[johntechwriter]

Too cool for school! How I'd love a 5-speed in my XJR.

[Haffschlappe]

Dont forget your driving gloves :)

[WaterCottage]

Did the Jaguar crankshaft have a pilot bushing hole in it already ?

[novom2001]

@WaterCottage Yes, the pilot hole in the crank is the same one that is used for the automatic's torque converter. You just need a bushing to suit your application.

[tylerwerrin41]

Hi Novom,

I did some research -- you can adapt the stock fittings to either An-3 or An-4. I plan on going with the An-4, just in case i upgrade to a stiffer performance clutch later on. If you are interested, the summit part # is: 641001 for an4, and 640281 for an3. How long was your clutch line from master to slave? I need to buy steel braided lines today :-). Also, i found a cheap slave cylinder w/ bleeder, which can be used as a replacement for the stock (92 camaro.)

[novom2001]

@tylerwerrin41 I used a steel line from the master to a homemade L - bracket which I mounted on the 3/8 bolt that holds the fender braces to the firewall. From there I used a flexible line of 12 inches or so to another L - bracket mounted on one of the bellhousing bolts, and another steel line from there to the slave. Basically I copied the way it is done on the E-type and I used E-Type lines and fittings. Are you planning to use a flex line all the way from master to slave?

[tylerwerrin41]

I am using a 1993 T56 6 speed Tremec transmission in conjunction with a 1993 Camaro LT1 5.7 engine. The bell-housing is for an LT1 style engine. The slave cylinder on the T56 is a 1" bore, which is pretty big -- i don't know what the E-type slave is. I think this is where our projects diverge a bit! I'm confused because the Camaro uses specialty hydraulic fittings for the slave which mates to the master...

[novom2001]

@tylerwerrin41 Looks like your car will be a blast to drive when you get it together. The E-Type master and slave each measure 7/8". I had never measured them before, but I always assumed that the master was smaller than the slave, having a longer throw. In your case, the E-type master working or not would depend on how much throw is necessary at the slave. Any way of adapting standard fittings to your slave?

[tylerwerrin41]

Hey novom2001,

I picked up the transmission/engine today -- very exciting! I had a question regarding your slave cylinder. Was the E-type master able to displace enough fluid to push the slave? or did you have to modify it?

[novom2001]

@tylerwerrin41 I used a standard bellhousing, clutch and slave cylinder from a 6 cyl E-Type, so everything works as it would on the E-Type. What type of bellhousing are you using?

[novom2001]

@novom2001 @tylerwerrin41 Just saw your video and the LT1 part sank in. Don't know how much throw you will need from the slave cylinder, nor what size the piston in your slave is, but I can measure the Jag parts and let you know, if that will be of any help.

[tylerwerrin41]

Thanks for the tip novom2001! I'll see if I can mimic your great results :-) With the LT1/T56, there is a lot of room between the bell-housing and the firewall (alot more than with the XJ6 components in place.) It is good news to hear that the E-Type reservoir can be used so easily -- I was worried i would have to fabricate extra stuff!

[novom2001]

@tylerwerrin41 Please let me know how it goes. It would be interesting to see how your project goes, and if I can help, I will be glad to.

[tylerwerrin41]

Wow, MKII must really be tall -- there is about 8 inches of space. I checked out the link -- thats really great you managed to get the 528i pedal into the pedal box assembly. E-type reservoir are pretty common thanks to all the restorers out there -- what did you use for the reservoir for that? I can see the little tank mounted to the left of your booster -- how is it piped?

[novom2001]

@tylerwerrin41 - The inner part of the bonnet actually takes up some of that space you are talking about. The MkII bottle could be used if you created space by relieving some of the bonnet metal. I used a brake fluid bottle mount from a series II XJ-6 (same as a XJ-S), and modified it to hold the e-type clutch fluid bottle. There is space to run the line between the pedal box and the firewall, if I recall correctly. I used a copper line with a short rubber hose connecting it to the bottle.

[tylerwerrin41]

wow -- nicely done. How did you modify the pedal box to add a clutch pedal to it? Did you use a master cylinder from an XJ6? I have been trying to find one for a month, no dice!

[novom2001]

@tylerwerrin41 The pedal box already has the boss to hold the clutch pedal. It is only necessary to cut the holes for the mastercylinder shaft and the pedal pivot. Master cylinder is from an E-type. The master for a MKII has the fluid bottle integrated into it, but the only one that I could find was too tall. Check out the link in my comments above for a little more info.

[novom2001]

Thanks, the idea came when one of my customers drove in in a 1984 XJ-S with a 3.6 L 6 cylinder engine and a 5 speed Getrag transmission. After driving that car, I was never quite at peace with the B-W slush box. I'm driving the car on my daily commute, and it seems to run better and better the more I drive it. I do have a couple issues that I need to work out, but they are not show stoppers.

[simulationdesignserv]

This is a very interesting video. I've looked at your site too and the manual conversion is impressive.