So it's finally done... almost. Actually it was done last weekend but I had to get home so I hung it up for the weekend. I broke my reverse light switch off in the trans... BUMMER! It was already screwed and wouldn't engage so I chucked it up in the lathe this morning (doesn't everyone have a lathe in their garage?) and wacked about .050 off of the shoulder to try to get it deep enough to engage on the recess on the shaft, but it decided that it wouldn't have any of that.

I also screwed up and used a cut down spacer between the firewall and master cyl. that made the peddle come up higher, but then the peddle wouldn't go deep enough to engage the safety switch for the starter. This dealio came with the mess of 89' ZF6 parts I scored on ebay, so I thought it went with the mas. cyl. This morning I switched to my original spacer. So then I was jubilant when, sitting on the doorsill with my right leg on the clutch peddle, and turning the key just to see if the switch would engage and if it would crank, it just fired right up!!! Never even heard the starter crank! Not bad for having sat for about six or seven weeks, sweet music!

So I know it's dangerous, but I ran through all the gears up on the jackstands, everything seems kool. But I have to say that the Hurst is just a little TOO short. I think it requires a lot of effort to shift, and it really has my arm down low on the console, like I'm reaching into the console to shift or something.

Also, the RAM single mass clutch is REALLY noisy. Just sitting in the car with it idling and the clutch out in nuetral, it makes a horrendous sound, almost like a rod-knock. If your going to go with this set-up, my advice is to find someone who has one and take a listen. I'm starting to think I might actually like it or at least, not mind it but I could see how it might not be for everyone.

Other than that, it was: new pan gasket, new rear main seal, new pilot bushing (used a 5/8 tap & bolt to get old out), RAM clutch disc kit, new pressure plate/bearing, new (Delco) slave cyl., freshened up 89' mas. cyl., DOT 5 synthetic (wish me luck I guess, found out on the Forum that it may not be the best idea), Hurst shifter, new u-joints (this time with zerks... hmmm), 89' ZF6 trans/bellhousing/fork, BMW synthetic motor oil in Trans., Mobil 1 synthetic (after years of Castrol Syntec), oh yeah, and two new rear Bose speaker/amp units, (Thanks Chucks88, they work great)

So soon as I score a new reverse switch I'll be able to drive it, then I'll post again with my thoughts. Tune in same time next week. Sorry, I don't have pictures to post, but it would've been great to show the aluminum floor section I built...

In the meantime, I have FOR SALE:

Two brand new GM tin bellhousing front covers left to fit the 89' to 90' ZF bell. These are discontinued. Needed one, wound up with three. (Believe it or not, they were at a truck dealership in NY and they had six of them, the last six left according to my local dealer search. They wanted me to buy all six, so I took three.) My costs = your costs... $3.81 each plus shipping.

Complete clutch pedal assembly from an 89', make me an offer.

Also have the original 4+3 shifter set-up, for an 88' with the swith on the ****, make me an offer. Everything else is sold, even the floor section I cut out! (thanks Rich B.)

meantime, SEE YOU IN HELL 4+3!!!!! :mad :mad :mad :mad :mad

good riddens....

 

:cheers: :cool:
I think you'll like having a 6spd.

 

yep. that's what I'm thinking.

 

Mooncricket you will love it. A whole new drving attitude:cool:
I did my 4+3 to Zf a few years ago. No looking back at all. I must say its one of the best upgrades I have done.

To all others thinking of the swap. The swap itself is not bad. Just get all the parts. The ZF literally bolts right in place of the 4+3. Cutting out the 4+3 shifter is no big deal.

Dennis

 

:lol: :D

Any chance of you making a template of the floor section you cut out? Might be handy for others.

 

Hey Scorp,

There really is no template to make. I just went about 1/2 inch around the shape of the well with my dremel and some thin cut-off wheels. Then I used the section that I cut out as a buck for the new one made of .125 aluminum. When it was close to shape, I sprayed it with machinist dye and set the floor section in. Then I scribed the shape of the hole on it and added about an inch all the way around for a flange and cut it out and cut the whole for the ZF shifter. Then I used some weatherstripping glue and rivitid the thing in. It's kind of tricky because you have to stretch the metal a little to get the shape, there is sort of a compound curve to it at the bottom.

Best thing to do is just get into it and make it fit as you go. I wish I had taken pictures, if it would help somebody else out.

Scorp, sorry to hear you smoked your motor at 175k, I was thinking of the same mods later for mine with 119k on the clock without doing the bottom end, now I'm nervous again and I'm thinking maybe I better wait and do the whole motor.

 

Thanks, but do not be afraid. It was my own stupidity that caused the engine to die. I got into a race and was low on oil (I hadn't checked it). The launch sent the oil away from the pickup and I lost oil pressure.