Tranny Transplant (Auto to Manual Conversion) (see below for parts list) |
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| As it was. One little pedal & one big pedal. |
No clutch cylinder yet. |
Box of parts. |
| The parts laid out. Not all will be required (some will be reused from my car). The things needed for sure: clutch pedal assembly with master cylinder, brake pedal, clutch, clutch plate, flywheel, slave cylinder, hardpipe, gear shift boot, lower engine braces (different for manual). See below for more complete list. |
The clutch assembly. Supposed to be an aftermarket unit. Its stood up to nearly 300RWHP so far. |
The tranny. Note short shifter mod and the drive shaft in the back (Ill have the U-joints replaced prior to install). |
Now there were three (pedals). I fit the pedals with shiny new pads. I added nice new pedal pads later. |
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| In goes the brake pedal. Pretty easy. Just a couple of pins. I've taken off the dash undercover and the heater/ AC pipe running under the steering column to get to this point. |
Now for the clutch. Had to pull off the pre-cut hole in the rubber floor mat to uncover the hole in the firewall plus the mounting bolt hole under the dash. Two bolts fit from the master cylinder through the FW and through the pedal assembly. A third bolt holds the assembly to the dash frame. This step is the worst PITA, but very doable. |
Here's a view of the master cylinder. |
Now onto the tranny. What a oily mess! |
| Out with the old. I first removed the driveshaft and exhaust. I could use my floor jack for this b/c the auto has a flat pan. Use something under the rear to catch the oil that pours out the back of the tranny. |
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| The old auto shifter. |
| Manual top, Old Auto bottom. (manual is shorter) |
| In with the new. Bolt up the flyweel first with a new pilot bearing. The FW bolts are longer than those for the flexplate. I had to rent a tranny jack b/c the manuals bottom is round. Very much worth the $35!! Note the clutch assembly in place on the tranny (new TO bearing). The clutch will bolt up when the tranny is in place. |
| The stock shifter hole. |
| Had to trim some for the manual shifter socket. It slid a little more forward as the tranny engaged and was bolted in place. |
| Note that the auto drivshaft (top) is shorter than the manual one. I forgot to count, but I believe the number of teeth is different at the input shaft end too. |
| This is the plug for the back up lights. I will have to rig up a new circuit with a new waterproof plug. This plug is on the passenger side of the tranny. |
| This is a view from the underside up at the old auto tranny plugs. There will be three unused. One plugs into the speed sensor that is located on the reat, drivers side of the tranny. |
| 07/07/02 At this point I have had my Supra out on the road. The manual tranny works great. I replaced my short shifter. I really didnt like the super short shifter mod that came on the tranny. I still have to get the back up lights connected and I have yet to test the cruise. I will post about that stuff as I get to it. I still have the Auto ECU in and it appears to be working fine at this point. I also havent hooked up the neutral start switch yet. On the manual, this is a switch on the clutch that allows you to start the car only when the clutch is depressed. I have a direct connection from the iginition through a relay (on the firewall) to the starter at this time. On the auto, the neutral start switch is actually on the tranny and plugs into one of the unused plugs seen in the last picture. |
| Parts List with suggested repairs/new{*} parts Manual tranny, manual driveshaft (get u-joints replaced ?), flywheel, flywheel bolts{*}, pilot bearing{*} for flywheel, clutch plate{*}, clutch disk{*}, throw out bearing {*}, clutch fork, lower and two side covers plates for tranny bell housing, slave cylinder {*}, hardpipe, brake and clutch pedal assembly, master cylinder {*}, shifter, shifter boot (* JCWhitney) with the lower metal frame, rubber cover for bottom of shifter, Manual ECU (maybe). If you find something I've missed, email me so I can add it to the list. ( jgrahammd@hotmail.com ) |