Final Manual Conversion Thread

[Chirijaden]

Bah! Ok I have started multiple threads about racing automatics, and the whole deal. I know about level 10 performance transmission kits, and everything. I already have an auto car, and it is impossible to find a thread with the price of a manual conversion. Many threads discourage purchasing autos, but no one answers the question of a manual conversion. So please I am begging, can people give me some quotes on manual conversions. I would like to know parts and labor. Or really whatever you can give me.

 

[irn__man]

Originally posted by Chirijaden
Bah! Ok I have started multiple threads about racing automatics, and the whole deal. I know about level 10 performance transmission kits, and everything. I already have an auto car, and it is impossible to find a thread with the price of a manual conversion. Many threads discourage purchasing autos, but no one answers the question of a manual conversion. So please I am begging, can people give me some quotes on manual conversions. I would like to know parts and labor. Or really whatever you can give me.

Here is one quote, I got in an e-mail.

Hiyoo doin ! These are just estimates.


trans- 1000 used

starter- 100 new

axles- 110 used or 275 new

act2600 clutch- 400

stock FW- 60 or fidanza 400

Mitsu parts to swap in from stick car- 1000 (pedals, clutch lines, etc, shifter assembly)

There could be more shit. This is what I remember off the top of my head. It isn't cheap, but my finished product will give you no clue the car was ever an auto! Just fun times bangin gears!!!

John N
BroadwayPerformance.com

Oh Yeah! checkout their website for labor charge =$1500


iron

 

[Chirijaden]

Well, that price is just way too far out of my range. So what do you think is the best way to create a performance auto without going over 1500?

 

[TalonXtreme]

try to find a car that is being parted out.

I'm doing this conversion on my 96' TSi. I picked up the pedals, shifter assembly, shifter cables, master clutch cylinder, and slave sylinder for 350 bucks. The guy even throw in a 5-speed console for free (all you need is the boot!)

I've heard that the axles can be reused. Please let me know if this is correct. i don't wanna have my car down that long over the summe!

You'll also need a starter from a manual transmission car.

I have YET to pick up a transmission since I'm on a budget, but I've seem them from $300 to $1000, most of them were around $450.

As for the flywheel and clutch. Look at this way, you'd need to purchase as these anyway if you HAD a 5-speed car. I'm gonna go with a resurfaced stock flywheel from RRE, and a NEW ACT 2100 clutch. This should be around $500

so lets see now:

350 for pedals/shifter/cables/master/slave/boot
500 for a used transmission
100 starter (new)
335 for a clutch

135 for a resurfaced flywheel.

That's $1420 Is it a lot of money yes! But I'd much rather spend that amount on something that will make my car faster, and add to the value of it. (NO BODY WANTS A AUTOMATIC PERFORMANCE CAR!) Then to spending that money on an body kit, cheap ass paint job, and a bunch of gheeeey stickers! (No offense to those with body kits!)

-Mike

 

[irn__man]

TalonXtreme,

I am looking into doing the swap myself, mostly doing the research now. I have a question for you though. My car is a 99 GSX, do you or would you happen to know how I can find out what year Manual transmissions or compatible with my current setup? I am thinking the the years from 96-99 would basically all be the same. But, l would like to know first before purchasing a bunch of parts.

Yeah! one other thing if you have a Shop do the work the total swap could cost anywhere from $3000 - $4000. That is a lot of $$$$.

thanks in advance
iron

 

[TalonXtreme]

Any 2g (95-99) GSX would provide you with the right parts. You could even use the pedals, shifter assembly, shifter cables, master cylinder, and slave cylinder from a 2g GS-T.


Goodlook on your swap!

 

[zac83]

i did it for FAR less than a grand total on a 1g AWD...

i got a 5 speed ratio 4 bolt rear center unit for 300 - COST price at a junkyard
5 speed tranny/t case was included with my JDM motor. (roughly cost me 300 bucks...)
parts tranny to rectify the JDM front wheel final ratio: 350
300 dollar parts car for pedals/shifter/cables/clutch slave and master (made 350 total off this parts car so its actually -350 on the total)
A couple various parts should be needed too.
While your down there, you could put clutch/flywheel/pressure plate on but that would run your total up quite a bit.

Basicly speaking: if you were in my area and had the parts, i would probably charge you for 8 hours of labor total for a job like this. anyone else would probably cornhole you on labor costs so i would do it for 400 bucks labor

anyone want a swap in the east texas area? ...

any other ?s give me a shout, i can tell you how to do it all.

 

[92TsiTalon]

well....actually....im in fort worth and im doing a swap on a '92. however, i also have the engine and tranny out of the car, so that makes it easier. these are prices ive come across:

t-case, shifter, shifter cables, flywheel, flywheel bolts, clutch master, clutch slave, clutch line, clutch/brake pedal assembly - $250

tranny - $400

rear differential (there is no difference in axles) - $100-$150

ACT2600 - $380

That's a total of $1130-$1180 for parts. Not such a bad deal.

Where are you in east texas?

 

[92Laser-T]

I'm currently in the process of having my auto switched to Manual. There is alot of work involved. The shop that is doin mine had to removed the ENTIRE dash for the pedals. drill a hole for the clutch lines. Also had to cut a hole in the firewall for the clutch cables. Need new CV's etc. Also check up on the nuetral safetly switch. I would say a good 2 days for the Job. I dont no bout prices cause it was part of the deal I made with the guy I do all my business through I traded moms 94 Explorer with bad tranny for Laser turbo includin tranny swap so it came out good. i figured even if it blows up in a day it'll give me a reason to pull the motor and build one up good luck though

 

[92TsiTalon]

thats ridiculous to remove the whole dash. all you really need to pull out is the steering column...or at least that's all i had to do. the holes that need to be made are already made in one layer of the firewall, so all you have to do is punch them out. ive found a couple of good vfaq's on it, and here they are:

http://www.kentallman.com/justin/transswap/
^
This one only works when the guy that made the site has his server running, but it has the best pics of the two.

http://www.ecanfix.com/~mdhamilton/autotomanual.html
^
This one is a 1G fwd swap. i think it might be a non-turbo, but it and the turbo swap should be similar

Hope this helps any auto to manual swappers.

 

[92Laser-T]

Hey thanks for the input on the dash. I guess it dont really matter for me because 1. i'm not doin it and 2. I aint payin for it to be done the hole is allready there but yes like u said u have to punch it out or whatever. I'm bout to get my car back hopefully tomorros so i'll post how well its doin. I was shiftin in and out of gears Friday and everything seemed to go in great. but i'll see i'll post how it went

 

[92TsiTalon]

well that's cool, as long as you dont have to pay for it (or do it because i dont think id want to take a dash apart...).

 

[Crazy29187]

Originally posted by 92Laser-T
I'm currently in the process of having my auto switched to Manual. There is alot of work involved. The shop that is doin mine had to removed the ENTIRE dash for the pedals. drill a hole for the clutch lines. Also had to cut a hole in the firewall for the clutch cables. Need new CV's etc. Also check up on the nuetral safetly switch. I would say a good 2 days for the Job. I dont no bout prices cause it was part of the deal I made with the guy I do all my business through I traded moms 94 Explorer with bad tranny for Laser turbo includin tranny swap so it came out good. i figured even if it blows up in a day it'll give me a reason to pull the motor and build one up good luck though

I thought the driveshafts didn't need to be changed on the 1G?

What did you guys do for the neutral safety switch? I saw nothing about it on the VFAQs. I think I figured out the reverse switch though by looking at the circuit diagrams. The two wires that the 1G VFAQ shows that you need to connect, I think the wires on each side of those two wires are for the reverse light. Can anyone verify this?

I think you could easily get this conversion done in a 1G, providing you do it yourself, for under $1,000, even with a performance ACT2600ish clutch. I feel bad for the 2G guys who actually do need the new driveshafts, along with a starter, and maybe some other stuff...

I'm going to do this conversion soon. Just waiting to find a transmission at a reasonable price and I'm gonna jump on it

 

[92TsiTalon]

i checked factory part numbers and the front axles as well as the rear differential are different parts than the manual stuff, even for the 1g. I also verified this with Robert at Forced Performance. Here's the parts list that about 3 months of research have gone into:

-Clutch/Brake pedal assembly
-Shifter and Shift Cables
-Clutch Master Cylinder
-Clutch Slave Cylinder
-Clutch Line
-Transmission
-Transmission Mount (only 1 for a 1G, 2 for a 2G)
-Transfer Case
-Front Axles
-Rear Center Differential
-And of course, flywheel and clutch

This is where I am getting some of the parts:

-Clutch Master Cylinder and Slave Cylinder from www.nopionline.com.
-Clutch Stainless Braided Line from www.darksideracing.com
-Resurfaced Flywheel from www.roadraceengineering.com
-ACT2600 Clutch Kit from www.slowboyracing.com

These are pretty good deals for these parts from what i've found. I found the clutch from Buschur for $10 less, but I like dealing with Slowboy, so I'll spend the extra change for better service (not saying Buschur is bad by any means, I just like dealing w/ Mike more)

I got all but the tranny and rear diff for $250!!! Found a guy parting out a '92 Tsi from dsmtrader. Should end up pretty cheap anywho. Hope that helped.

-James

 

[Crazy29187]

Hmm, I just assumed that the shafts were the same because the VFAQ said they were, but I got CAPS here and you're right. Only SOME models had the same axle for both trannsmissions.

Here's the part numbers for the 1G models:
Part Number/Date/Transmission/Remark
Front Axles:

D21A 1800:
MB526438 - 8805.1-9405.1 ALL GREEN
MB297992 - 9011.1-9405.1 ALL D-GREEN

D22A 2000/2WD (No remarks):
MB297872 - 8805.1-9006.1 ALL
MB297872 - 9006.2-9206.3 M/T, M/T with Turbo, A/T
MB620612 - 9006.2-9206.3 A/T with Turbo
MB297872 - 9207.1-9405.1 M/T, A/T
MB886798 - 9207.1-9405.1 M/T with Turbo
MB886800 - 9207.1-9405.1 A/T with Turbo

D27A 2000/4WD:
MB526438 - 8903.1-9006.1 ALL GREEN
MB526438 - 9006.2-9305.3 M/T GREEN
MB620314 - 9006.2-9305.3 A/T
MB297992 - 9011.1-9305.3 M/T D-GREEN
MB297992 - 9306.1-9405.1 M/T D-GREEN
MB526438 - 9306.1-9405.1 M/T GREEN
MB620314 - 9306.1-9405.1 A/T GREEN

Rear Axles, I cant find them in CAPS. Its weird, when you click on the part that seems to be the whole axle, it is the boot kit. Anyone know those numbers and dates? And whats the difference between Green and D-Green?

Strange, from those numbers, you can use any axle from a 1.8L on any AWD M/T model, but not on a FWD M/T.

As far as the rear diff and the transfer case, I knew those had to be changed. Thanks a lot for informing me how dumb I was for assuming about the axles

 

[92Laser-T]

Well I'm happy to say the Switch over is completely finished. There were a few set backs but the Car runs GREAT and pulls like a champ. This is my first time ever bein in a DSM and i'm in love. I need some help with some stuff though. For some reason none of my Dash lights, brake lights, and turn signals work. I havent had the chance to look anything over bein that I got the car an hour b4 work. Tomorrow I'll check all the fuses. Does anybdoy know another reason for this if its not the Fuse. Has anybody ever had this problem b4. Thanks for the Help

 

[92TsiTalon]

hmm...that's strange...my first guess would be the fuses. you also might want to check and see if the harnesses were even plugged in when the swap was completed. you have to disconnect them to get them out of the way, so just check right up under the dash and fasten any harnesses that are plugged in and connect any loose harnesses. just a thought.

 

[92TsiTalon]

It would be really nice if someone could make this one sticky as it has TONS of manual swap info (wink, wink)

 

[Crazy29187]

Originally posted by 92TsiTalon
It would be really nice if someone could make this one sticky as it has TONS of manual swap info (wink, wink)

I'll second that

Anyway, 92TsiTalon, how about this list I got. I copied all the things you said were necessary for the swap and expanded upon them to figuure out where you could acquire the different parts. These are for a 1991 AWD swap, although other years would probably be similar.

Major Parts:
AWD Manual Transmission with mount
91-94 23 Spline

M/T Transfer Case
91-94 23 Spline

M/T Rear Differential
90-91 3 Bolt (4 bolt if you want)

Flywheel
6 Bolt, resurfaced with .610” step height

Clutch Kit
ACT 2600, etc.

Minor Parts:
M/T Front Axles
MB526438 or MB297992 (Any 1G 1.8L or 2.0L AWD M/T, not 2.0L FWD)

Master Cylinder
MB555133 (Any 1G model/year)

Hydraulic Clutch Line (3 parts)
MR151524 and MB555368 (any 1G model/year), slave MD724458 (1G AWD)

Slave Cylinder
MD733623 (Any 1G AWD)

Pedal Assembly
90-94 (Any model/year)

Shifter Assembly
91-94 (Any model/year)

Shift Cables
91-94 (Any 91-94 AWD)

I verified these parts through both partznet.com and CAPS, so they should be close to right, but I have been wrong before. I think to be a good reference, there should be a list like this that tells you what parts to get, and more importantly, from where, depending on the transmission you want to use. Like in my previous post, the 1.8L models have the same axles we need, so they could be a cheap source. But, someone should make sure I didn't mess up first

 

[92TsiTalon]

That...my friend....is the best manual swap parts list i've ever seen...with the part numbers and all.

Maybe we could get some feedback on these Tokico Master and Slave cylinders from Nopi because they are a TON cheaper than the ones from the dealer.

I've got a great idea. Anyone doing a swap, send me a full vfaq with the specific parts and install option you chose as well as your own information on you and your car. Ill put those together with mine and we can make one freakin' awesome VFAQ. Or we could just call it the Swapping from Auto to Manual - For Dummies. I don't know, its just an idea, and I know I'll have the time and means to do it so let me know what you guys think.

oh, and, 92Laser-T, maybe you could come up with some resources from the mechanic that did your swap so we can get all the information we possibly can into this guide.

good idea? bad idea? lemme know

 

[92Laser-T]

So far everythign Is going great. Its worth it as long as u or ur mechanic knows what there doing. I'm very happy so far. Today I figured out why my lights werern't working. I needed to plug in 1 connector and bam all my dash instruments work blinkers and everything. i do have to get a speedo cable though no biggie. As far as the install I no they had to customize the Clutch cables to match up with the tranny perfect. I no they had to cut a hole in the firewall for the Master cylinder. and for the cables. I'm gonna get a Cam with some pics so I can post some pics of the install along with my new Leather interior I installed

 

[92Laser-T]

Clutch cable bracket not the cables itself

 

[92TsiTalon]

yea, i was lookin through my cd service manual, and there is a connector that controls all of that. the service manuals are great.

so...he just had to modify the cable bracket and not the cables, right? i wouldnt think that you'd have to modify the cables, but i have no idea about the bracket.

 

[Crazy29187]

If I'm understanding you correctly, one of the VFAQs talks about this. The 90 transmissions have cables that only fit that transmission, while the 91-94 transmissions also have cables that only fit those transmissions. The last three pictures on this page show what I'm talking about:

http://vfaq.com/mods/shifter-diffs.html

 

[92TsiTalon]

oh, i didnt realize that there was a swap of one into the other.