CONVERTING AUTOMATIC TO MANUAL GEARBOX 2.1 DJ

[thebobster]

My automatic gearbox on my 1990 2.1 DJ powered van has given up the ghost.

One option would be to convert the van to a manual gearbox. I know there will be problems but one thing I need to know is this; can my DJ engine with suitable flywheel fitted accept the input shaft from a manual gearbox?
I have been told that there may not be a socket on the end of the crankshaft to accept it because the input on the auto box comes from the torque converter without touching the end of the crankshaft.

Any advice on this problem will be welcome. Thank you.

[Aidan]

yes it'll work, you will have to fit a flywheel and a spigot bearing and felt washer and clutch instead of the flex plate, you need the box mount clutch pipework and cylinders the two pedal set and the stick and linkage appropriate to your set up, 2wd petrol/how ever many gears, accelerator connections for normal engine and in a perfect world a manual DJ ecu
ideally find someone breaking a DJ van

[CovKid]

Struth Bob, lost of cost there.

[thebobster]

Thank you very much for the valuable information, Aidan. I know you don't touch auto gearboxes otherwise I would have been on to you like a shot for a rebuild.

Ralph, it's a case of damage limitation. Auto gearboxes to suit the DJ engine seem to be scarcer than unicorn feathers and nobody I have been able to contact is able to repair them any more as the parts have been obsolete for over 10 years. At least if I convert to manual, I will still have an asset whereas all I have at the moment is a rusty liability.

(Another club member, (Mick from NW parts) has informed my mechanic that he can supply the necessary parts for the job, so there is light at the end of the tunnel which is not just a train coming towards me.)

[Budgie7]

Hi Bob, I also have an auto and have thought about changing to a manual should the same happen. My box changes up really smooth but clonks quite bad when going into reverse , especially when hot. I don't know if this is a characteristic of the auto or not
I can't believe how scarce the boxes are but hope you sort it out one way or another, keep us posted
Barry

[thebobster]

Thanks for the comment, Barry. I have had to take the decision today to convert from auto to manual. All the bits are available used but I will be fitting a new clutch assembly and one or two other bits. I am now on annual leave for a few weeks so it is now I need the van! All being well, I should have it back by this time next week. (Fingers and everything else crossed)
With regard to your 'clonking' in reverse gear, the only thing I have noticed is that because mine runs on LPG and petrol sometimes the engine idle speed is a bit faster on LPG than on petrol and when selecting reverse gear the gear 'clonks' as the drive bites, it only 'clonks' the once and then runs smoothly. Is that what you are experiencing? As a matter of fact, my van will still move in reverse gear but nothing happens when you select any of the forward settings. It is not the control cables either, it is definitely the gearbox itself that is kaput.

[thebobster]

My horse has long since bolted, but other people with auto gearboxes may be able to shut their stable door in time. This article makes essential reading for those who own but don't know much about auto boxes and their strange innards.

http://www.gowesty.com/library_article.php?id=305

[Oldiebut goodie]

ER - kids are off school again!

[thebobster]

ER - kids are off school again!

Meaning?

[Oldiebut goodie]

'Meaning?' ...?

13 posts in 20 minutes! Same rubbish on each.

[silverbullet]

Oh yes! Thats loaded up the timeline a treat...

[Sir Brixalot]

Good article. Is the cooler warning just trying to push sales or is the warning sound advice?

[thebobster]

Good article. Is the cooler warning just trying to push sales or is the warning sound advice?

I think it may be good advice personally, I noticed a drop in the ATF level on the dipstick without ever seeing oily marks on the ground where it is regularly parked so it makes sense at least as far as that. One job I will be doing on the strength of that advice is to drain and flush the cooling system before using the van again. Belt and braces!

[Budgie7]

Hi, Bob, yes it only clonks the once when you first engage reverse, but only after a run when it's warm.
Am going to keep fingers crossed and hope its stays ok, as there is no way I can afford to convert it, even though I work in a garage for a living and my labour is free.
If I can hopefully get the summer and some camping done then maybe I will look at converting it in the winter.
All the best anyway and if you ever need a ramp for an hour or two let me know
Barry

[thebobster]

All the best anyway and if you ever need a ramp for an hour or two let me know
Barry

That's a generous offer, Barry, thank you very much.