Parts needed for 5 speed swap???

[Speach1]

Just curious as to all the parts I would need to do this swap in the future. Also if anyone's done this swap tips??? tricks??? I have other things to do that are a bigger priority but I would like to prepare myself for the job if I ever come across a manual van in a junk yard.

[groundown]

Howdy,


I did this swap about 3 months ago and found it to be pretty straightforward, everything literally bolted into the existing chassis.

From front to back you will need:

The clutch/brake reservoir and hose to connect the clutch master

Clutch pedal assembly, this piece replaces the solo brake mount on the auto and comes with the clutch pedal, neutral safety switch, clutch master, and the brake booster all attached

Shifter assembly and shift cables

Passenger side engine hatch/lid, the manual version has two holes in it versus the one hole on the automatic version

Transmission w clutch slave cylinder, metal bracket for shifter cables, and all trans mounting hardware up to the chassis

5spd driveshaft


Things you’ll need to adapt/fudge:

Reverse light connection

Clutch line from master to slave cylinder, I had mine done at a local line shop

Clutch neutral safety instead of automatic park safety switch

Any gauge retrofitting if you dont already have a tach

Shifter boot



There’s also a little guy called a clutch accumulator but opinions vary on whether its useful or needed, so I’d say Google is your friend on that one.


If you can purchase a cheap donor vehicle to part out and then scrap, thats the ticket. Its a long day at the yard getting the whole dash apart to access the clutch pedal assy. You can also yard out all the bits folks on here are always in need of, intake boots, corner lights, door handles, etc


But its a very doable swap and totally worth it if you’re into manual, much easier to find usable power:thmbup:


If the time comes and you have any questions feel free to PM me

D

[Speach1]

Dude. Your awesome! Thank you. I'm glad I asked because I would have totally not thought that I would need the engine cover. Where is the neutral safety switch located? I know those things can be in odd places. If I remember correctly on the auto trans its mounted right in front of the shifter under the cover. Yea old school japanese stuff needs to be manual in my opinion. Just plain cooler and more fun to drive.

[groundown]

My pleasure! Your timing is pretty funny, I actually just took down the ‘5 spd swap’ I had listed in parts for sale, due to total lack of interest. Feel free to keep it in mind, Its all the bolt in stuff but none of the consumables, and in light of shipping costs you’d probably want to just get a rebuilt tranny.

But I have the reservoir, pedal assembly, shifter assembly, trans mounting brackets and crossmember, and driveshaft.

So you’d need the tranny, a clutch kit, master and slave, and a clutch line: all of which would be worth investing in new. Also the forementioned passenger tin.

Its all in functional but not very pretty shape, surface rust, dustbunnies in the shifter, etc

Anyways, keep it in mind if you dont find a local donor.


Regarding the neutral safety, I think the sensor was actually at the transmission but I jumpered it in the engine bay pending a rewire to the new clutch switch.


Excited that someone else is headed down this road, be sure to do a better job than I did postings pics and progress:doh:


Oh, and welcome to the forum!:)

D

[Speach1]

Ah man. Thanks. Yea I think I'm just going to wait for now. Any idea where i could find any of this stuff new? Ill be hunting forever if I don't find most of this stuff in one place.

[originalkwyjibo]

Passenger side engine hatch/lid, the manual version has two holes in it versus the one hole on the automatic version

An alternative to obtaining a bulky engine cover would be to use a hole saw to cut the additional hole(s). This is what I did when I converted my 4WD auto to a dual range transfer case. If I remember correctly, the manual shifter uses the same hole as the auto plus one more. Also, I think there was some dimples or other markings indicating where the other holes should be located. Older Japanese stuff is usually very easy to reconfigure as they build them for nearly every option. I once swapped my wife's 1978 Honda Accord from a 2spd Hondamatic to 5spd manual in about five hours including changing motor mounts, instrument cluster, distributor, vacuum solenoids, and pedal assembly. The job was barely more then if I had just been doing a clutch. The most challenging and time consuming part was swapping the pedal cluster. The holes for the master were already there with a block off plate bolted in place and the wiring was plug and play as well. I would suspect with a little digging the wiring on the van would be as well. Sometimes alternate connectors are taped up into the harness in the vicinity of the the component they connect to.

[groundown]

This is what I did when I converted my 4WD auto to a dual range transfer case.


?! WHY ARE THERE NO PICTURES OF THIS ?! I will wait patiently while you post some..
(To clarify: This is me being excited about the dual range conversion, not angry about pictures, lol)

In the case of Auto to 5spd I ran into problems w just drilling another hole, although I started w the same hope/plan. But the single Auto hole sat just inbetween where the two 5spd holes needed to go, basically slightly overlapping each. After scratching my head over how to figure out the right layout, drill two clean holes, and patch the gap inbetween so the boots would seal correctly, I decided the factory tin better met my needs. I was a little worried because the donor was an 85 and mines an 88 but it bolted in just fine. If he’s pulling parts already I cant think of a better way to save time and hassle than the factory tin.

The modular nature of that general vintage of import is pretty awesome. My friends always joked about how my 5spd swap would ‘just bolt right in’ but thats exactly how it went, lol.


Speach1:As far as new parts RockAuto is your “friend” although in an era of free shipping they will get you all excited w cheap parts and then make you sad when “calculating shipping” but they carry a wide variety of price points for most given items, including Aisin which I recommend if only for peace of mind.

You will only find the infrastructure parts I offered you from a donor though, or kindly west coast benefactor, as far as I know:wnk:

Another benefit to buying a parts van is that you can figure out disassembly technique on something you dont care about. The biggest PITA of the whole thing is taking the dash apart, everything else is very accessible.

D

[originalkwyjibo]

But the single Auto hole sat just inbetween where the two 5spd holes needed to go,
I see. While I grabbed the five speed as well as most parts needed to swap from the same van as the t-case, I have not pursued the tranny swap so was unaware of the difference. I had assumed the auto used one of the hole locations for the five speed. Thanks for the clarification.