Here I will document and post about my work converting an AJ16 to a T5 manual transmission popular in many jag conversion , notably Harry Metcalfe has one behind his V12 XJC .

I’m a kiwi in NewZealand , and getting a Getrag 290 isn’t realistic , neither is having one sent from the uk.

Borg Warner / tremec T5 have a huge aftermarket with many variations and parts available.

the project scope is
*use a common variant - mustang v8
*use off the shelf parts
*use auto bell-housing , starter and flex plate ring gear
design a flywheel
*design a tidy adaptor plate
*use an aftermarket hydraulic bearing
*retain the automatic ecu and electronics
*design a drop in brake pedal
*design a clutch pedal and system to work with an automatic pedal box .

 

So a few more notes

The adaptor plate is to be laser cut, a simple spigot turned in a lathe keeps the ZF bell-housing concentric .

I have ordered a 1990 mustang v8 clutch kit, the oem rating of a standard ( not heavy duty ) puts it right at 400nm


the hydraulic release bearings are necessary to avoid complications of using an automatic bell housing , there are many kit suppliers /

I have designed the brake pedal but not started on the clutch pedal - these will be cnc profile cut fabricated parts .

reslly the next step to to get the clutch kit so I can design the flywheel . The next components are reslly the slave bearing kit and a master cylinder .

im expecting a bit of pain on getting the hydraulic system right so a bench test setup will needed .

 

This template is to become a 3mm stainless steel profile cut piece which bolts to the casting to “put back” the missing pivot tab .

Second design at a pedal came out particularly nice , to be 12mm or 1/2” profile cut mild steel.

The tilton 76 master isn’t a direct fit on the Center hole , I’d like to avoid machine work if possible so it’s a bit more of a bolt on kit .

Tilton website has been very helpful to provide the necessary ratio and travel for the clutch pedal .

 

The mustang 10.5 clutch and pressure plate is an easy fit in the ZF 4HP24 bellhousing

 

It looks like the bolt in clutch pivot conversion is going to work , this is just an extra pedal box for development . I will be using the immaculate one from my low kms car /

its 2mm mild steel thats been profile cut . I need to drill and tap the thick bit to m10x1.25 and weld it to the thinner piece . It’s more for the reason of it being a captive nut than anything else . I think with a second layer of 2mm plug welded on to the area by the clutch pedal near the bolted tabs it will be sufficient strong .

It’s already very stiff even with 5 m6 and one m8 bolts but can’t be too careful.

There are lots of needle roller / bronze bushings with a 10mm bore that can run directly on a ground shank shoulder bolt . now that the pivot point exists I can set bout designing a clutch pedal .

 

Today I’ve been to see an x300 on the hoist with the transmisson removed .

for anybody doing something similar the ring gear is basically flush with the engine back plate . To the face of the flex disc is 5.5mm and to the face of the crank ( not the spigot the face itself ) is 24.5mm .

the tolerances on these measurements will be about -+ 0.25mm