My Peugeot 607 V6 Z9 Auto To Manual Transmission Conversion Project

Ikenna351

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Fellow Frogger
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Nov 9, 2010
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Location
Abuja, Nigeria.
*ABOUT THE SUCCESSFUL CONVERSION PROJECT OF MY PEUGEOT 607 V6 PHASE II (Z9) FROM AM6 AUTOMATIC TO MANUAL TRANSMISSION.*

The project of the new born maniac started on 08/01/2019 and ended on 30/05/2020 (17 months). A tough excited project, considering every part of the vehicle system was designed to work with just Automatic transmission (AM6). It appeared no one else has done this Conversion before I did (since I couldn't find one online yet). There could be though, for I really want to hear from those that have done it too and their experiences.

I originally set out to convert with 6-speed Manual gearbox, but decided to go for 5-speed Manual, since my excitement couldn't keep me waiting for 6-speed Manual box that was taking too long to locate. However, I needed to do the conversion to work with both 5-speed & 6-speed Stick-shift, Incase the 6-speed turns up in future. For that, I had to study or researched on parts for such conversion to be a reality. To successfully do the conversion to turn out the way I want, my findings led to parts from about 3 different Peugeot models. A tough challenge and exciting one too.

Almost everyone I told about the project said the project will destroy the car, except one or two men that were excited when when I told him about the project, in our usual private chats/discussions, that reside outside Nigeria. I never listened or gave a rip about public opinion anyway. If I wanted something that has nothing to do with anyone else, it's done. It's a question of when, as long as the financial and physical strengths are there.

30/05/2020 was the day I cranked the engine and it roared into life with the Stick-shift box for the first time. The drive that followed after was unforgettable. The car now move like a different car: less weight, quicker, less fuel consumption and most importantly, *PREDICTABLE* , just like my other Stick-shift V6 lions. Words cannot describe the fun part of the drive. I get to now play with the pedals, while I watch the 3.0i ES9A 290 Nm torque surge the car forward like a maniac he has become. Thanks to the brand new Valeo clutch kit and Total Manual Transmission Fluid Gear 8 75w-80.

Even with the complex electrical system of the car, wired to work only with Automatic Gearbox, I did the Electrical part of the conversion so well that the car now work as if it originally had manual transmission from new. No warning sign on the instrument panel. The ABS, ESP, Variable steering, variable suspension, engine cooling fan, instrument panel, Multifunction display, etc, everything works the same way before the conversion took place the previous week (yet to make out time to reconnect the parking Aid though).

I now have a perfect Z9 V6, exactly how I wanted it from the beginning. The AM6 6-speed Automatic Gearbox was still running like new at 77,000 km mileage before I removed it, but wasn't part of my dream Z9 V6. As new and good as the AM6 gearbox is, it's not for Lion King - Monk. It denied me self Expression Behind the Wheel I couldn't ignore or live with.

What about the original intention of 6-speed Stick-shift box? Few days of driving the lion with the 5-speed Stick-shift has been so exciting that I no longer care if I see or don't see the 6-speed box. But I am still looking out for one.

I can't wait to conclude other projects on my other lions as well. So many good things in this physical life for men to choose and enjoy. I mean, if you find life so boring or uninteresting, get rid of your car and get a fun one, for you can only find yourself in that frequency/condition when you surround yourself with boring things. Or at least, do something about it. Just yesterday, I took the new maniac for another drive, applied some skills on the pedals and gear lever and found myself screaming *YEEHAW!* I drove back home and closed the celebration with a bottle of 1759. I mean, I beat my chest, pointed to the car and said *I DID THAT!* (boastfully). One of the best part of masculinity which I am proud of.

Ikenna351, Lion King - Monk.

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I will make out time to post some pictures taken during the conversion. And possibly the cost of parts used in the project.

Ikenna351, Lion King - Monk.
 
*COST OF THE PROJECT* :

So, like I pointed Out earlier, started gathering parts needed for the conversion in January 2019 and concluded the conversion on 30/05/2020. Cost of some of the parts purchased are as follows:

1. ML5C Manual Gearbox:. $130 USD.

2. ES V6 Flywheel: $13 USD.

3. Manual pedal assembly (brake & clutch):. $57.

4. New OEM Clutch Master Cylinder:. $26 USD.

5. New OEM Clutch Slave Cylinder:. $31 USD.

6. New OEM Clutch Kit (Pressure plate, Friction plate & release bearing):. $117 USD,

Etc.

The project cost me Total of $950 USD to conclude. Unfortunately, out of the $950, about $211 was scammed out of me by some of my fellow Nigerians while sourcing for some of the parts from Nigerian part sellers that are not my trusted contacts. It was a huge loss, but I didn't let it discourage me and I kept on till I completed the project successfully.

Yes, I met a lot challenges in the project and in the process acquired a lot of technical knowledge on Peugeot systems in relation to conversions. The Z9 V6 has similar mechanical and electrical systems with D2 V6 (407 V6). Meaning D2 V6 Saloon won't be a problem for me anymore or anyone in interested doing identical or similar conversion.

Hope that helps anyone interested in Converting Z9 V6 or D2 V6 to Manual.

Ikenna351, Lion King - Monk.
 
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