Installation instructions - CJ5 for all E Types  
Congratulations on the purchase of your CJ5 - the ultimate five speed conversion for your E Type Jaguar!
Your kit should contain the following items:
The following only applies to 3.8 E Types:
Installation Tips

Unlike any other transmission kit on the market, your new CJ5 five speed transmission is exactly the same length as your old 4 speed (6 cylinder, SWB E Type) and does not require the removal or modification of your original driveshaft. In the case of V12, 2+2 and XK CJ5 transmission kits, a brand new driveshaft is included with your kit.

The CJ5 five speed is the only Jaguar conversion kit in the world that uses a brand new, custom made input shaft. Our competitors modify the T5 input shaft, machining it down to the required size. At Classic Jaguar we have manufactured our new input shaft to be compatible with standard Jaguar clutch componenets, including the standard Jaguar clutch disc.

Stand the CJ5 bellhousing on the ground and carefully lower the CJ5 transmission into position on top of the bellhousing. Note: You will only be able to do this with a 6 cylinder CJ5 transmission, as the V12 input shaft is too long to allow you to stand the gearbox on end with the bellhousing on the ground. Secure your CJ5 bell housing to your CJ5 transmission using the 1/2 - 1 1/2" bolts and lock washers supplied.

Install your original clutch fork into the new bell housing in the normal way making certain that you have installed the locking grub screw that secures the clutch fork.

Install your clutch slave in the normal way, making sure you have sufficient free play.

Using a regular clutch alignment tool, install the clutch disc and your 9.5" diaphragm pressure plate to your flywheel in the normal way.

Mate your CJ5 transmission to your engine using the original fasteners.

Prior to installing the engine and gearbox, screw in your original Jaguar angle drive to the speedo drive installed in the tail housing of your CJ5. If you forget to do this now, it will still be possible to install the angle drive with the transmission in the car, although it will be very fiddly!

You may find it easier to fill the transmission (which is shipped dry) with transmission fluid at this stage. We recommend Castrol Syntec Dexron III Mercon ATF (automatic transmission fluid) or Mobil One synthetic ATF (automatic transmission fluid). Fill up to the level of the filler plug marked 'A' in ther photograph below. The capacity of the transmission is a little less than 2 quarts. Important! You cannot use regular gear lube in your CJ5 transmission because doing so would cause damage the carbon fibre synchro rings. Automatic transmission fluid must be used! Using gear lube may void your warranty!

In order to gain access to the filler plug from inside the car, some people like to cut a small hole in the right side of the trans tunnel. The hole can be sealed with a rubber body plug when not in use. In the Classic Jaguar workshop we prefer to simply fill the transmission from beneath the car, which is a simple process with the car on a lift.
A = filler plug B = drain plug
Offer the engine and transmission into place in the normal way. Once you have secured the engine mounts and the rear (firewall) stabilizer, secure the front of the drive shaft to the flange already pre-installed to the rear of your CJ5 transmission. New drive shaft bolts have been pre-installed in the output flange for your convenience.

Next, offer the rear transmission mount up into position. The Delrin spacer block fits directly beneath the rear shelf of the tail housing and the steel trans mount plate bolts to the floor of your car in exactly the same way as your original 4 speed trans mount plate. Use the 7/16 - 1 3/4" fasteners supplied with your kit.

When correctly installed, your CJ5 tranmission will be smoother and more quiet than any Jaguar four speed gearbox. Any significant mechanical noise is an indication that your transmission is making contact with either the trans tunnel or the trans cover. In such circumstances, simply reposition the transmission away from the point of contact with the tunnel or trans cover.

Now offer your speedo cable into place and secure it to the angle drive you (hopefully!) installed in the tail housing earlier.

Connect the reversing lamp switch (using the pigtail harness supplied) to your existing Jaguar harness.

Now, using the bolts supplied with your shifter, secure the stainless steel shifter to the black CJ5 shifter assembly.

Connect clutch hydraulics and bleed clutch in the normal way. Install sound and heat insulating foam over the top of the transmission as per the OEM transmission, then reinstall the transmission cover. Take care not to damage the transmission breather (see photograph below)  when installing the insulation and the trans cover.


Transmission breather
Note: With some V12 installations it may be necessary to cut some relief into the rear most part of the trans cover to allow the cover to fit snugly against the firewall without the cover fouling against the transmission. Most E Type trans covers will bolt into place in the normal way, although it is essential that you make sure that the trans cover does not contact the transmission (see note above regarding trans fouling against body).

Once you have installed all the other engine bay ancillaries, you are ready for a test drive. We strongly recommend test driving before reinstalling all the interior trim. This will save you a bunch of time if it is necessary to address any issues that come up during the test drive. In fact, at Classic Jaguar we test drive new installations even before installing the trans cover, although great care must be taken in these circumstances because the spinning driveshaft is exposed and could cause serious injury!

Important! The installation of an E Type engine and gearbox (of any type) is a potentially dangerous exercise due to the weight of the components involved. Access to a quality shop lift makes the operation easier and safer. Installation of such major components should only be attempted by qualified persons.

Warning! You should never test run a CJ5 ( or any manual transmission, for that matter) through the gears with the rear wheels raised off the ground. Quite apart from being dangerous, slamming the gears in this way may cause damage to the transmission and may void your warranty!

If you have any questions about your installation, please do not hesitate to call us on 1 877 PART JAG or (512) 288 8800. Alternatively, our Technical Support email is constantly monitored and all questions will be answered promptly.

Good luck and thank you for your purchase!

Dan Mooney
Team CJ