ZF4HP22 Conversion

[BartStag]

Hi everyone,

I hope that all are well.

I wonder if anyone can offer some advice regarding the ZF4HP22 conversion that I am currently doing.

I would have loved to engaged Clive Tate to do it as his reviews are really good, however the financial effect of the pandemic and the fact that the Stag is a driver not a show piece have led me to take on the conversion myself as I don't think I would ever get the money back.

I have started with a ZF4HP22 gearbox & torque converter from a 3.6 Jaguar XJS, I purchased an adaptor plate and have successfully fitted that. I have successfully fabricated a new gearbox mount, gear linkage etc and have found solutions for the inhibitor & speedo.

The car now starts and runs, selects forward and reverse gears however I am having a problem with the converter hitting the bell housing at the pump end? When I set it up I left a clearance of 2mm between the flex plate and the converter mounting plates. I have 2mm spacers welded on the converter to facilitate the converter clearance and when the box is bolted up without the converter to flex plate bolts fitted the converter spins freely. I am afraid that if I remove the welded 2mm spacers the pump to converter lugs will not engage properly?

I have even gone to the lengths of removing the sump and renewing the crank thrust washers and now have a clearance of 0.004", so I'm right at the low end of the tolerance of 0.003 to 0.011"

I am starting to wonder if the converter for the 3.6 Jag is the wrong converter to use? I understand that there are three versions of the 4HP22 converter available, can anyone offer any advice on the correct converter.

Any help or advice would be much appreciated

Best regards

Steve

[Wheelz]

I have just refitted an engine to a car with a ZF gearbox, and the problem I had was that the starter ring gear was fouling on the bottom of the bell housing. This was a puzzle because apparently this engine/gearbox combination had been running OK before the engine was removed. I could see no alternative but to remove some excess metal from the bell housing and then refit the gearbox, and this seems to have resolved the problem.

Are you sure its the converter hitting the bell housing and not the ring gear?

[BartStag]

Hi Chris

Many thanks for your reply.

It is definitely not the ring gear on the bellhousing, I have fitted a BW35 bellhousing with an adaptor plate an the clearance on the ring gear is good.

My problem is the rear of the torque converter hitting the bellhousing at the rear where the converter enters the auto box, you can see slight witness marks. I have trimmed some of the ribs from inside the bellhousing but no joy? As I said I am loathe to reduce the spacers on the converter much more for fear that it will affect the converter pump drive.

From memory I think I read a post from someone who said that the Jag converter is too large, but I can't find the article now.

Steve

[sujitroy]

Hello Steve,
I'm interested in doing a DIY conversion. Alan Thomas on this list gave a me a document which I'm reading. He talks about an end float. I'm sure Alan wouldn't mind me sharing this document. I just picked up a ZF4 from a local guy for 100$ here in USA. It came out of a BMW. He says folks throw them out as no one wants them. They convert their cars to manuals. Where did you purchase an adaptor plate from?

Regards, Sujit

[sujitroy]

What's the best way to address the dip stick?
Sujit

[mole42]

What's the best way to address the dip stick?
Sujit

"Sir" usually seems best

[new to this]

What's the best way to address the dip stick?
Sujit

you may have to rebend it