Automatic to Manual Conversion

[Adamaga]

I could not find a thread detailing exactly what is involved converting from an auto to a manual.

I have seen some people mention that they have done the conversion but that's all the information I could find.

I would like to know roughly how much it will cost (for both the parts and labour fitting them), what bits I need (gearbox, pedals, master cylinders, etc) and how easy or difficult it is to do.

Thanks.

 

[finx]

i have done several of these conversions myself.
if your not very mechanically mined then its not a task to tackle yourself.

im unsure what the cost would be to you as your on the other end of the earth. but the following parts are what you will need

gearbox parts

gearbox
flywheel
flywheel bolts
rear engine mount bracket (gearbox side)
rear engine mount (chassis side) and bolts to match.
LH side engine mount
LH side engine mount bracket
manual gearbox bell housing bolts
manual starter motor
manual starter motor bolts


clutch parts

clutch kit (clutch plate, pressure plate and thrust bearing)
if installing a new clutch kit (this is recommended) get the flywheel machined.
clutch pressure plate bolts
clutch release fork
clutch release fork boot
clutch slave cylinder
clutch slave cylinder bolts
clutch master cylinder
hydrolic clutch lines short and long steel lines and the rubber line
hydrolic clutch line brackets and clips
clutch pedal bracket
clutch pedal bracket nuts
clutch pedal
clutch pedal rubber
clutch pedal spring

other parts

manual brake pedal
shifter assembly
shifter cables x2 one of each type
shifter cable clips x4
shifter boot
gear nob
manual dash cluster (optional)








common misconceptions and facts/things that need doing:

the auto drive shafts do fit the manual gearbox
the auto loom needs to be modified
in gt's and glanzas something needs to be done about the ignition lock as the cable is connected to the auto shifter (ep71 this isnt necessary)
same for the dash cluster in ep82 and ep91's have the auto gear selected lights which aren't needed so a manual dash is a good idea
hole needs to be cut in the firewall for the clutch master cylinder which doubles as the mounting for the clutch pedal bracket. this is the hardest part of the conversion

i think thats about it, getting late and my memory is a bit slushy

i can put up some links on the conversion if required

cheers
ryan