I am looking for info won what all I need to make the transistion into the Manual transmission society...lol I have a 2004 Cav with the stunningly smooth and torquey 2.2L Ecotec. I know I will have to swap out the comp and (of course) the tranny, but could it really be that simple?
not really easy... not really hard. a LOT of little and medium stuff
you need to punch a hole in the firewall for the clutch pedal assembly to go through
you need a brake pedal (manuals have a smaller brake pedal)
clutch pedal assembly
clutch master cylinder, reservoir & lines
transmission mounts (pretty sure the 4t40e doesn't have the getrag mounts)
I'm not sure, but I think you'll need the getrag driveshafts as well
flywheel (to replace your flexplate)
clutch (be sure to get one that comes with the slave cylinder ie: SPEC)
then you need:
shifter assembly
shift cables
center console from manual car
then you have to plug up the tranny cooler lines from the radiator.. this is easy just flush it out then leave em open if you never plan on using it again.
and to finish out the list either a 5 speed ecu, or reflash the car with HPT with a 5 speed program. Your wiring harness won't plug into the getrag either. You can convert it, but i'm not sure how you need to talk to John Lenko.. I'm sure he'll find his way into this thread.
I think thats everything.. but I haven't done the swap just yet.. Adiktid2speed's car may be the first I try this on
Yeah, you take out the engine and trans, grind off the auto mount tab... weld in two brackets for the manual trans... put on all the associated stuff..
It's not terribly hard, just get all the parts together ahead of time. I didn't hack up my wiring, I swapped the entire engine bay and dash wiring harnesses.
Putting in the clutch pedal is a pain... you have to pull the whole dash to get to it. And remove the auto -size brake pedal and swap in the manual one too.
