Si_s Supe Posted May 27, 2014 Share Posted May 27, 2014 I may be just about to acquire a manual donor car. So I'd have everything needed at my disposal. What exactly will I need to swap over to FULLY convert my car to manual? Quote Link to comment Share on other sites More sharing options...
Josh42 Posted May 27, 2014 Share Posted May 27, 2014 Gearbox Bellhousing Clutch release fork Clutch release bearing Pilot bearing Clutch kit Flywheel Prop shaft Diff Slave cylinder Master cylinder Clutch hose(hard and flexi) Manual brake pedal Clutch pedal Shifter Manual gear surround Manual tachometer Manual gear tunnel cover Possibly manual loom or adapt the auto loom Quote Link to comment Share on other sites More sharing options...
Si_s Supe Posted May 27, 2014 Author Share Posted May 27, 2014 The main thing I was wandering was the loom. Do I need to change the entire loom?? Everything else is just a straight bolt-off / bolt-on. Quote Link to comment Share on other sites More sharing options...
Josh42 Posted May 27, 2014 Share Posted May 27, 2014 You can modify the auto loom to run the manual box very simply...I did it on mine for the last 2 years but I've now moved to a manual loom. The other thing to consider is your transmission tunnel cover. Quote Link to comment Share on other sites More sharing options...
Si_s Supe Posted May 27, 2014 Author Share Posted May 27, 2014 Does the transmission tunnel need to be modified for the R154 5-speed? I thought it was just for the V160 6-speed? Quote Link to comment Share on other sites More sharing options...
Josh42 Posted May 27, 2014 Share Posted May 27, 2014 Yes, the tunnel is not tall enough to accept any of the manual boxes. It's not a difficult job to change but 100% worth it Quote Link to comment Share on other sites More sharing options...
Si_s Supe Posted May 28, 2014 Author Share Posted May 28, 2014 Ok, what's involved in the tunnel modification? Quote Link to comment Share on other sites More sharing options...
Si_s Supe Posted May 30, 2014 Author Share Posted May 30, 2014 Can anyone that's done this tell me, or point me in the direction of what is involved in modifying the tunnel? Looking for hands on experience as I'd like to do this myself, but need to know exactly what's involved before getting stuck in. By the way, correction for above, it's a W58 not R154. It's the standard NA transmission. Quote Link to comment Share on other sites More sharing options...
David P Posted May 30, 2014 Share Posted May 30, 2014 See pics here. http://www.mkivsupra.net/vbb/showthread.php?296229-James-s-DJG-Turbo-Project Quote Link to comment Share on other sites More sharing options...
Si_s Supe Posted May 30, 2014 Author Share Posted May 30, 2014 Excellent, thanks David! Doesn't look TOO bad!? Fancy doing another one?? Lol. Is it do-able on axle stands? Not likely to get on a ramp for the conversion. Also, is it likely I could remove the manual tunnel from the manual car and it still be re-usable on my car?? Quote Link to comment Share on other sites More sharing options...
Josh42 Posted May 30, 2014 Share Posted May 30, 2014 I did mine on axle stands. Was easy enough. I riveted and sealed mine in. Quote Link to comment Share on other sites More sharing options...
Si_s Supe Posted May 30, 2014 Author Share Posted May 30, 2014 Ah, was going to ask if it could be riveted. Does it make up and massive structural / torsional rigidity? Quote Link to comment Share on other sites More sharing options...
Josh42 Posted May 30, 2014 Share Posted May 30, 2014 I'd hope not seeing as though it's only a few mm thick and I managed to do this: to my old one when removing it Quote Link to comment Share on other sites More sharing options...
David P Posted May 30, 2014 Share Posted May 30, 2014 I'd hope not seeing as though it's only a few mm thick and I managed to do this: http://img.tapatalk.com/d/14/05/31/ehevagah.jpg to my old one when removing it This one came out clean enough to live again. Quote Link to comment Share on other sites More sharing options...
theredone Posted May 31, 2014 Share Posted May 31, 2014 Manual looms dont work on a manual converasion, i had to adapt the auto loom to make mine work Quote Link to comment Share on other sites More sharing options...
theredone Posted May 31, 2014 Share Posted May 31, 2014 And yeah its easy on axle stands, i had no choice but use them haha, i thought it was easier taking the engine out Quote Link to comment Share on other sites More sharing options...
Si_s Supe Posted May 31, 2014 Author Share Posted May 31, 2014 Manual looms dont work on a manual converasion, i had to adapt the auto loom to make mine work Thanks mate, any info on the adaption required? I had thought that seeing as I have a full manual donor car, I could swap EVERYTHING to make it manual? IE, the obvious running gear, clocks / ECU / loom / sensors / switches? Quote Link to comment Share on other sites More sharing options...
Josh42 Posted May 31, 2014 Share Posted May 31, 2014 And yeah its easy on axle stands, i had no choice but use them haha, i thought it was easier taking the engine out Why don't manual looms work mate? Little worrying as I'm about to put a manual loom into mine... Quote Link to comment Share on other sites More sharing options...
theredone Posted May 31, 2014 Share Posted May 31, 2014 Because the manual car has a few different sensors i think mate, my manual loom didnt have 2 plugs that went onto my steering rack, and wouldnt let the ignition work or fuel pump, so i adapted the auto loom by splicing the neautral start position switch wires together and also the reverse light wires Quote Link to comment Share on other sites More sharing options...
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