Full f40 conversion
 

Since i can not find a single person that has eve successfully completed a f40 conversion. I will start that i purchaced zzp's kit that has turned out to be bull shit so I will give full part numbers and directions with pictures. So far it is close to 1k including a new trans if you do not use zzps kit that they sell for 2k alone and states on their sire that it would work for a f40 from a 2011+ Regal 2.0t but as i have found out the hard way that is not so much the case it has to be a f40 out of a saab 9-3 2.0t if not nothing that they sell will work except for the factory parts.

So now that I have said that i am still currently in pricess of making this work since zzp kit is a no go you can pick up a new 2011+ regal trans off ebay for 500 shipped.

Over the next couple days will be updates and part numbers for my conversion.

the info on their site contradicts itself. taken right from their site

i always remember them saying its designed for the 2007+ saab f40. what they are claiming is the early saab f40 and 2011+ regal doesnt have the gearing you want for a cobalt.

can you post pics with what physically wont bolt up and work as described? im interested in seeing it.

There are several ppl who have completed the swap. I'm sure one of them will chime in. I personally wish they made a f40 with a LSD.

You are right is does contradict it self it says that the gearing is not optimal but also says it will work but mostly designed for 2007+ SAAB but i did also reach out to them and they said it would work and durring install realized diferent i contacted them back about it and have got no response. I will post pictures on monday when i go back to work it is on my lift at the shop

what sort of things dont work?

I'm doing my swap with a 2010 Saab transmission just haven't had the time to do it

First, if you did indeed search on this forum thoroughly you would've found TONS of info on this subject and a handful of users that have completed the swap.
Second, the ZZP website info states it will work but it doesn't have optimal gearing. So why would you spend 2k for the swap kit and use a trans with crappy gear ratios in the first place? Seems like a waste.

Optimal gearing says zzp lol and if you search you dont find tons of info but some scattered info and no one that has done a f40 swap with a brand new regal trans.

All done i am extreamly happy with the trans shifts are so smooth and nls like a mofo. Gear ratio is perfect for power and also curently getting great mpg

good to hear its working for you. do you have pics and info on the stuff in the zzp kit that didnt work for you with the regal trans?

So you ended up going with the 2011+ regal trans?

Yea more info about your swap would be great

Hey, as long as it works for your needs and you're happy with it, that's all that really matters anyway. I'm glad it worked out for you. :twothumbs

As others have asked, please include the information about what issues and differences you came across using the regal trans.

Sorry to bump an old thread, but I'm curious if OP ever finished this and got it running. Got a question for yas ....


Gonna plug this here btw: https://github.com/bgeorgeiii/redline-f40

Hahaha I have more than a year without time to do the swap

I blew up the F35 in my Redline and couldn't stomach what appeared to be like ~$1500 for a rebuilt unit, and didn't trust a used (of unknown quality) unit for the going rate of $800+ at the time, which of course doesn't include the cost of the clutch / flywheel / fluid etc. On top of that my car spends 95% of it's time on the highway at 75mph+, the gearing on the F35 wasn't ideal to say the least.

So I embarked on just doing the Regal swap myself. The whole swap using all new parts, including the transmission itself was about $1700. I've got >20k miles on it since last summer but I'm having TOB issues. Blew apart one within 6k miles, the second lasted 15k. I'm thinking it has to be the modified clutch pedal / adjustable clutch master cylinder I was running. Currently I'm looking into swapping to cobalt pedal / master cylinder. But I'm wondering if anyone else is using the Regal trans and run into TOB problems. My setup has the OEM clutch, flywheel, and TOB so the only thing that makes sense to me is the modified pedal / master cylinder setup.

I can't believe I've never seen this thread but I havent seem any tob problems on my f40 trans which has about 10k on it and 467hp 450tq abused every time I take car out with stock clutch

Are you using the Regal trans?

Saab 08

Regal f40
 

So I embarked on just doing the Regal swap myself. The whole swap using all new parts, including the transmission itself was about $1700. I've got >20k miles on it since last summer but I'm having TOB issues. Blew apart one within 6k miles, the second lasted 15k. I'm thinking it has to be the modified clutch pedal / adjustable clutch master cylinder I was running. Currently I'm looking into swapping to cobalt pedal / master cylinder. But I'm wondering if anyone else is using the Regal trans and run into TOB problems. My setup has the OEM clutch, flywheel, and TOB so the only thing that makes sense to me is the modified pedal / master cylinder setup.[/QUOTE]

I know it's been a while, but just hoping you got this sorted out and remember. I have an hhr, currently sitting at the 450 whp area. Last week I took it to the track and attempted 1 hard launch. It started pouring fluid about halfway home, but still shifts, pulls, and sounds good. A little wine but there is practically no fluid now. ( when it started pouring I was like 2 miles to the house so... I got there) Now I'm debating if I should bother fixing this f35 or if I should go the expense of an f40. Can prolly find a donor car somewhere. If I had the donor to take parts from, do I need a kit still? What is needed to put it in my hhr?

I'm guessing you cracked the case so fixing yours is most likely not going to be economical. And honestly you are going to break a lot of F35s at that level. You can ramp in the boost to help keep them alive, but my guess is you'll be on borrowed time.

As far as getting a donor, I'm not sure tbh. Really depends on what condition it's in and how much you can get it for. You'd still need mounts, driver side axle, and a fix for VSS. For VSS you can bore the hole for the sensor and use the F35 sensor. I personally ran a 2.2 crankshaft position sensor as it was a smaller diam so I had less material to remove. That sensor / connector is also pretty cheap and easy to find. Mounts you can get from OTTP. They also have 2 opts for LNF driver side axles now (reuse pass side). I have the DSS axle and tbh I hate it. Im sure it's strong, but it binds on hard turns. I've had it fixed by them once and it was good for like a month. I gave up and when it breaks completely I'll just get the stock replacement from OTTP, which is substantially cheaper as well. Not sure if that'd be recommended for your power levels though.

For comparison, I'm guessing you are looking at about $1000 for the factory parts if you purchase new and you go with a factory clutch / dmf (zzp $400). Plus the cost of the transmission, there's a few on ebay for $5-600 shipped.

F23 is an option, as well. I did a complete F23 swap for under $1000 - over half that cost was buying billet mounts (you can use stock F23 mounts) and new axles. It's lighter, less expensive, and more plentiful than the F35 or the F40. And the cherry on top is that there are a handful of final drive options to choose from.

Any updates on your swap? Pics, info, ect.?