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D2 - Transmission Gearboxes, diffs, drive shafts.

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Old 5th December 2017, 11:05 PM
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Default 98 2.8 having 96 4.2 swap

As above guys, swapping the 2.8 in a d2 for a 4.2 from a 96 car iirc, we are not 100% yet but the archaic 4 speed may be in disrepair, how hard is a 5 speed going to be to mate up with a PFL car and 4.2 swap?

Thanks in advance
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Old 5th December 2017, 11:12 PM
HPsauce HPsauce is offline
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Go manual?
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Old 5th December 2017, 11:18 PM
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Is it easy? Depends what’s easiest and ultimately cheapest
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Old 5th December 2017, 11:19 PM
HPsauce HPsauce is offline
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I wouldn't have a clue but several people here are working on it......
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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Old 6th December 2017, 07:27 AM
ainarssems ainarssems is offline
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Going manual is neither easy or cheap, lots of parts needed and lot of custom work hours. I am not sure how well will it work with the newer gearbox but 2.8 have weaker ZF5HP19A gearbox instead of ZF5HP24A on 4.2 so reliability could be issue.
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Old 6th December 2017, 07:43 AM
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Quote:
Originally Posted by ainarssems View Post
Going manual is neither easy or cheap, lots of parts needed and lot of custom work hours. I am not sure how well will it work with the newer gearbox but 2.8 have weaker ZF5HP19A gearbox instead of ZF5HP24A on 4.2 so reliability could be issue.
I think we’d end up using a 4.2 5 speed not the one in a 2.8 then, they seem to be more robust than the 4 speed as well(?)
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Old 6th December 2017, 07:48 AM
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The 4 speed box in the PF cars was always thought by most to be more bulletproof than the later 5 speed in the FL cars etc
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Old 6th December 2017, 08:14 AM
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Ah ok thanks, when googling the box it seemed to be problematic but then again, If you google a cold you’ve got breast cancer

Maybe worth keeping it in then iirc the G195 sensor is playing up on the donor Car hence the questions.
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Old 6th December 2017, 08:50 AM
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Quote:
Originally Posted by Burnzybubbles View Post
As above guys, swapping the 2.8 in a d2 for a 4.2 from a 96 car iirc, we are not 100% yet but the archaic 4 speed may be in disrepair, how hard is a 5 speed going to be to mate up with a PFL car and 4.2 swap?

Thanks in advance
4 speed is a better box IMO as it does as it's told and it's seemingly more reliable in the long run.

Quote:
Originally Posted by ainarssems View Post
Going manual is neither easy or cheap, lots of parts needed and lot of custom work hours. I am not sure how well will it work with the newer gearbox but 2.8 have weaker ZF5HP19A gearbox instead of ZF5HP24A on 4.2 so reliability could be issue.
Agree, it's not a MK2 Escort. Manual is a dream for most unless you either have loads of money you want to poor into your 8 or are really good with the spanners. It was 5 years ago I posted I didn't think it was in the realms of most people and as far as I'm aware there is 1 RHD 8 we know of been done and working, MJ's to follow soon for sure.
Most 8's are not driven hard enough to warrant it, manual conversion for the 3 times a year you actually thrash the living pi** out of it, banning off the rev limiter in every gear, brakes smoking, clutch stinking, tyres shredded. The rest of the time stalling at junctions and roundabouts because of forgetting about the new clutch pedal.
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Old 6th December 2017, 04:25 PM
MikkiJayne MikkiJayne is offline
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The manual swap is never going to be cheap, but soon it should be pretty easy

Notwithstanding it being made from cheese, the 5HP24a from a PF V8 is probably the easiest option if its already a 5-speed car, along with the engine harness and TCU from the same. You'd need a new prop (shorter), possibly also rear diff. Can't remember if the front shafts are the same between the 19 and the 24, but there are plenty of 5HP24a shafts about. Shifter should be the same. Oil cooler lines, radiator and the front panel are all different.
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