What's involved in doing a DIY ZF4 conversion

[sujitroy]

Not that I want to pay upward of 3k UK Pounds for one, but if I was able to source a gearbox, what mods will be needed?
Sujit

[sujitroy]

Found this.

It is (Clive) Tate and (Russell) Lewis who developed the conversion. Clive only does sell & fit, but I believe it can be sourced and fitted through Faversham Classics and, maybe, EJ Ward. The kit is not available for owners to purchase.

For the money you get a fully reconditioned gearbox, reconditioned torque converter, bespoke bell housing, bespoke tailshaft to drive the Stag speedo, a new prop shaft, bespoke gearbox mounting, modified gear change, and a full guarantee.

It has been done as a DIY project (I’ve done it) but it isn’t straightforward. You need:

Gearbox (modify pump housing), adapter plate, modified BW35 bellhousing, modified torque converter, BW65 propshaft, modified gearchange, fabricated gearbox mounting. You also need to sort out the inhibitor and reverse light switches. Sort out a speedo drive - either develop and electronic conversion for the Stag speedo or purchase an electronic speedo and sensor. A batch of Stag electronic speedos were commissioned by a SOC member, but I don’t know if there are any left.

Would I do it again? Probably not. I did it as a challenge, but having now done so, I appreciate the value of the ‘proper’ conversion.

[DJT]

^^^ What he said. Did it myself (with guidance from others) 8 years ago and am very pleased with it, but would not do it again.

[mole42]

I bought my car with a ZF 'box already fitted. Probably the cheapest option.

[Tonywhite]

I have ZF four speed automatic gearboxes if you can’t find one

[jbuckl]

The zf conversion is involved. The result is astonishing.
DIY is not that straightforward.
The kit that T&L did, but now only supply fitted here includes:-
New bell housing cast & machined.
New output housing cast & machined.( when required, with new speedo drive)
New propshaft.
New mounting brackets.
New cooler pipes.
New dipstick & tube.
New harness.
New kickdown cable.
speedo cable new.
Adapted torque converter cleaned & checked.
Core rebuilt zf box.
Bolt kit.
When they supplied the kit, the only extra item needed was oil!

Doing all this as a one off takes time and effort.
Replicating it in any quantity is 10 times the effort, at least.
Big up for the zf in a stag!
imho better than Borg Warner or manual.

to do it yourself involves replication of the list above.
the bw35 bell housing can be adapted.
the speedo can be done with a magnetic pickup.

other car make & model specialists offer a service to provide a zf kit fitted, but at a much higher price (2x+)

[SaskStag]

I bought the kit from Monarchs when it was available and had a local transmission place install it. I have a spare BW35 bellhousing if you need one Sujit.

I just need to adjust the kickdown now I have Strommies. There was a Weber carb when the gearbox conversion was done.

[alan_thomas]

If you PM me your email address I’ll send you a rather long word doc that explains the DIY conversion. Have done 2 conversions myself and very pleased with results
Alan

[RobinLegin]

I invested in the Tate and Lewis 4 speed conversion. It is simple. They have the car for a few days, they hand it back all done. Simples - the uncomfortable bit is parting with the money. But IMO well worth it if you are keeping the car any length of time and if you’re planning any long distance trips. Cruising at 80kph on French motorways is a doddle and more fuel efficient.

[RobinLegin]

Sorry 130kph.

[jbuckl]

I invested in the Tate and Lewis 4 speed conversion. It is simple. They have the car for a few days, they hand it back all done. Simples - the uncomfortable bit is parting with the money. But IMO well worth it if you are keeping the car any length of time and if you’re planning any long distance trips. Cruising at 80kph on French motorways is a doddle and more fuel efficient.

Its a super thing to have…
But sujitroy is in the USA, so he needs a kit….

[RobinLegin]

Oh dear. Perhaps Clive wants to open a US franchise?

[jbuckl]

Oh dear. Perhaps Clive wants to open a US franchise?

There are valid reasons that a kit isn’t offered these days!

[RobinLegin]

Clive told me of the challenge he had with a Belgian client!

[Stag Esprit]

Probably the best mod you can make to an automatic Stag.
Clive did a fantastic job on “Eleanor” . Driving back I thought I was in a different car!!!
Worth every penny !!!