RRPhil is an extremely knowledgeable person to chip in with the real technical details of the gearboxes.
As regards the issues ... the GM is known to wear out and the valves are a commonly replaced / upgraded aspect to address the some of the common issues ( search for sonnax valves upgrade - basically a rebuild effort ). In sport mode, the shifts are made with more force so that the gears change quicker and snappier ... this may explain by it changes better in sport mode.
It also means that in normal mode the box is struggling.
Have you ever serviced the box and changed the fluid / filters, or have you just added a litre of fluid into whats already there. If I'm honest, adding a snake oil fluid to a box ( which wasn't designed to have that fluid in it ) thats showing signs of failing is only trying to mask the issue ... and postpones the inevitable.
A 6sp ZF box is not a drop in fit ... i think the ZF box is a lot smaller i think. V8 or else ...
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