Part 1 - Theory: Convert Auto to Manual D2a Td5 HSE. Please join to have fun first

[maxperformance]

Hi all,

I searched and found this question was discussed sometimes before but not a direct relation to a D2a HSE Td5 (or if I could not search it out?).

This is my topic to prepare for a (future dream) plan of doing a conversion of a D2a Td5 HSE from Auto to Manual. I want to understand the details with your helps before I could start the project with my mechanic (who actually accepted to do the job but told me that he has never done any job like that before and also he is the guy who wants to stay away from Landrover or BMW or European cars ).


So [B]please jump in and share with me anything you know about this conversion, I really mean anything because it will help my project could be kicked off or brushed off (and I swear I will put a hot gun on my mechanic's head to force him reading this topic before doing the conversion [thumbsupbig])

Some questions I bring in to have you help me to answer.

1. Could I use a D2 manual parts for the conversion or we have to use a D2a manual parts?
2. Buying parts, or get a full working donor D2 is better idea?
3. What are parts we need to remove/swap?
4. Can we just unplug the ECU and BCU from the donor to plug into the HSE? or we have to swap the whole wiring loom together?
5. What are links or guides if you know anyone did the same work before?
6. Any feature from HSE that likely work or not work after that?
8. Any tips in removal / installation / modification?
9. Any other ideas are more than welcome.

Thanks heaps!
James

[redmond]

ring or go to landys performance at south windsor they will steer you in the right direction and will be happy to do it for you good luck

[Tins]

Considered this myself at one point. But I didn't do it as a manual donor car was not to be found at that time. I have done it on other cars, and IMO a donor car is almost essential, for the myriad of little things you will overlook in your planning. However, depending on your budget for this, I would highly recommend getting an R380 from Ashcrofts. Get a few other toys as well.

[Blknight.aus]

for the auto to manual conversion you can cross mix between D2a and D2 parts although prudence says you're better off sticking with the D2a parts as they will be the newer parts and hopefully in better condition.

so long as you have the donor car complete for pulling the manual and parts out of you wont have any issues with the conversion. but briefly

youll want everything from the flywheel housing backwards to the tcase in terms of the transmission stuff,
you'll want the clutch pedal housing and plate
you'll need to reprogram the ECU and BCU to make it aware its no longer an auto.
you'll need the clutch switch harness (just so you can disconnect it later)
you'll need to hack the neutral start switch system (if turning off the bcu/ecu doesnt ignore it for you)

if your donor as a running engine and you're happy with it it can be quicker to just drop the entire engine/trans in as a matched pair then reprogram the brains if you go this route generally you can just carry the ecu over with the engine (although you will need to reprogram the security features)

The tcase can have a different ratio manual V auto if it hasnt been changed already (or if it has been modified) and from this point any reference to gearbox or auto infers both the gearbox/auto includes the tcase

if you buy your donor with a toasted engine...

do it in 5 to 6 stages

pull the engines, convert the auto engine with the manuals back end (replace the clutch/flywheel if the budgets easy)
pull the gearboxes, marking and noting the harnessing as you go, sell the auto, if its in known good condition you can get enough for it to cover a reasonable clutch and good flywheel
measure up and modify the tunnel covers as required and install the clutch pedal face (you have to pull the brakes down to do it properly)
install the gearbox
install the engine
work up the electricals and reprogram as required.

[maxperformance]

ring or go to landys performance at south windsor they will steer you in the right direction and will be happy to do it for you good luck

Thanks, I will keep this in the note.


Considered this myself at one point. But I didn't do it as a manual donor car was not to be found at that time. I have done it on other cars, and IMO a donor car is almost essential, for the myriad of little things you will overlook in your planning. However, depending on your budget for this, I would highly recommend getting an R380 from Ashcrofts. Get a few other toys as well.

Thanks, you have the same thought. I definitely consider to have a full working donor on the side rather than collecting parts to do the job. R380 from Ashcrofts with Heavy Duty TC would be one great option too.


for the auto to manual conversion you can cross mix between D2a and D2 parts although prudence says you're better off sticking with the D2a parts as they will be the newer parts and hopefully in better condition.

so long as you have the donor car complete for pulling the manual and parts out of you wont have any issues with the conversion. but briefly

youll want everything from the flywheel housing backwards to the tcase in terms of the transmission stuff,
you'll want the clutch pedal housing and plate
you'll need to reprogram the ECU and BCU to make it aware its no longer an auto.
you'll need the clutch switch harness (just so you can disconnect it later)
you'll need to hack the neutral start switch system (if turning off the bcu/ecu doesnt ignore it for you)

if your donor as a running engine and you're happy with it it can be quicker to just drop the entire engine/trans in as a matched pair then reprogram the brains if you go this route generally you can just carry the ecu over with the engine (although you will need to reprogram the security features)

The tcase can have a different ratio manual V auto if it hasnt been changed already (or if it has been modified) and from this point any reference to gearbox or auto infers both the gearbox/auto includes the tcase

if you buy your donor with a toasted engine...

do it in 5 to 6 stages

pull the engines, convert the auto engine with the manuals back end (replace the clutch/flywheel if the budgets easy)
pull the gearboxes, marking and noting the harnessing as you go, sell the auto, if its in known good condition you can get enough for it to cover a reasonable clutch and good flywheel
measure up and modify the tunnel covers as required and install the clutch pedal face (you have to pull the brakes down to do it properly)
install the gearbox
install the engine
work up the electricals and reprogram as required.

Thanks a lot for your great write up, it makes me a lot clearer in details.

[Kaaaiju]

Well as far I am an aware the lt230 is the same ratio for auto and manual d2,

I got an Ashcroft r380 gearbox last year built with HD bearings and 5th gear and it was $3400 landed and did the clutch and lt230 at the same time so might be worth doing that

The pedal box will have to be swapped as well
Thanks, I will keep this in the note.



Thanks, you have the same thought. I definitely consider to have a full working donor on the side rather than collecting parts to do the job. R380 from Ashcrofts with Heavy Duty TC would be one great option too.



Thanks a lot for your great write up, it makes me a lot clearer in details.