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Starting the N/A to turbo, auto to 5 speed conversion


14u2nV
Resident Pedobear


Galant VR-4 org Post #: 222850 posted 05/31/05 12:43 PM     Remind Me!  Send Private Message   Edit Post      
Well, it's started. Here's some beginning pix, and I'll keep adding more as I get further along.
Before:

Parts needed, and a side by side comparison of the pedal assys

Shifter assy with side by side comparison of vr4 shifter and dsm shifter (dsm shifter installed in pic)

Shifter assy with a little blingage since I'm gonna cut out a stainless plate instead of a boot.

Hole to use for pattern for clutch master cylinder.

Engine bay before:


Sorry about the pic quality, these are scanned. I'm gonna be getting a digital cam soon. I will add more pix and tips as I continue to progress.

Here's more:


The manual shifter is a direct/bolt-in replacement for the auto shifter.





Edited by 14u2nV (06/02/05 04:54 PM)

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mistaVR4
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484/1000


Galant VR-4 org Post #: 222852 posted 05/31/05 12:44 PM     Remind Me!  Send Private Message   Edit Post      
Thats quite a project man! Can't wait to see the progress. You have any pics of that shifter plate yet



SteveW
484/1000 Kensington Grey - Running VERY well :-)
564/2000 Belize Green ~ SOLD
749/2000 Summit White ~ SOLD
1989 Chrysler Conquest TSi SHP ~ SOLD
2004 Saab 9-5 ARC ~ Daily Driver



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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 222853 posted 05/31/05 12:46 PM     Remind Me!  Send Private Message   Edit Post      
No, havn't even drawn it up yet, but I should be able to get that tonight, and then maybe cut one out this week.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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lpfan989
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Galant VR-4 org Post #: 222878 posted 05/31/05 01:51 PM     Remind Me!  Send Private Message   Edit Post      
hey man when ur done you should post a full parts list and tutorial on how you did this. i am planning on doing the same thing hopefully

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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 222884 posted 05/31/05 02:02 PM     Remind Me!  Send Private Message   Edit Post      
I can put a parts list for the tranny swap:

*Pedal assy from vr4 or other manual galant
*Shift linkages from same
*Clutch master cylinder/line/slave cylinder (autos have the mount above the tranny
where the soft/hard lines meet)
*Shifter assy (from what I have looked at so far, it is a direct bolt in replacement,
I'll investigate this more though)
*Manual tranny/clutch
*Consoles look a little different where the shifter comes through, but it may work
**Radiators are a little different, auto has trans fluid lines. They may be interchangeable, but since I have the one out of the vr4 too, I'm using it.

-- There will no doubt be more, and I will add to this as I go along as well.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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Monsterbishi
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Galant VR-4 org Post #: 222930 posted 05/31/05 03:40 PM     Remind Me!  Send Private Message   Edit Post      
I did a auto-manual convo on my old E39A, the shifter linkages go through a completely different place to the auto, once you have the auto trans out(the 2nd mosy frustrating part of the whole job) It's easiest to drill/cut the new hole.

Installing The pedal boxes are the worst part of the whole job, lotsa upside down, and knuckle scraping...

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Rice Killer
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Galant VR-4 org Post #: 222936 posted 05/31/05 03:54 PM     Remind Me!  Send Private Message   Edit Post      
Kenny your LOCO, maybe I'm just lazy but I would of started out with a Manual to begin with, there cheap anyways, and that is just too much work for me, but if you have the free time go for it.

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<3s Rance and self distrusts
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1025/2000
553/1000


Galant VR-4 org Post #: 222938 posted 05/31/05 03:56 PM     Remind Me!  Send Private Message   Edit Post      
im with keith on this one, why didnt you start out with a manuel



_Ricky-
464/2000-sunroof
'95 Lancer Evolution III

2005 Mitsubishi Lancer Evolution VIII
"Give a man a fish and you feed him for a day. Teach a man to fish and you feed him for a lifetime"

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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 222962 posted 05/31/05 04:42 PM     Remind Me!  Send Private Message   Edit Post      
Ohhh, lets see. I got the GS for free, in great shape other than the engine, which I have a couple of. The reason I"m converting, is cuz the engine is bad, and the tranny is starting to slip, so I opted to put the manual in since I have all the parts anyway. Plus, it will help others decide not to, uh , I mean if they want to do it. I love doing this kind of stuff, and it gets me more in tune with my tuner self.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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SEVEN26
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Galant VR-4 org Post #: 222973 posted 05/31/05 05:08 PM     Remind Me!  Send Private Message   Edit Post      
good for you. its a big and avoidable project to undertake, but it will be well worth it i'm sure.

i can't wait to see the stainless shift boot. are you going to maching the 1g shifter arm to be the same diameter throughout? i think that would looke best but i dought the arm is on solid peice.

i know it would looke a lot better with a relatively thin arm and a ball shift knob. or something that would flow into the arm.

i don't mean to overcomplicate something small. you have bigger things to worry about but its certainly something to consider.

i'm just trying to visualize what would look best.

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91VR4NNJ
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Galant VR-4 org Post #: 223001 posted 05/31/05 06:33 PM     Remind Me!  Send Private Message   Edit Post      
Good luck with that project, I remember when we did the mx6 atx-mtx that shit took 12 hours straight

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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 223052 posted 05/31/05 08:50 PM     Remind Me!  Send Private Message   Edit Post      
If I try to make the shifter thinner, I'll just make a completely new shifter> Might look into that anyway,, one piece, one diameter out of stainless or alum, with a matching knob and cover plate.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 223584 posted 06/02/05 03:21 PM     Remind Me!  Send Private Message   Edit Post      
Here's where the magic is going to happen:


My long term project:



Notice any galant parts in there? There's enough in that garage to make a whole car.


Edited by 14u2nV (06/02/05 04:48 PM)

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iceman69510 Galant VR4.org Moderator
Turn Right Racing
855/2000


Galant VR-4 org Post #: 223590 posted 06/02/05 03:58 PM     Remind Me!  Send Private Message   Edit Post      
You already have a car with a big "hole" in it, why make another?



91 VR4 855 Nile Black
92 VR4 828 Belize Green-SOLD
91 VR4 115 Nile Black -SOLD

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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 223604 posted 06/02/05 04:57 PM     Remind Me!  Send Private Message   Edit Post      
That car is gonna be my project, and won't see sunlight till I'm satisfied. It's not dead, it's hibernating.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 224318 posted 06/04/05 10:51 PM     Remind Me!  Send Private Message   Edit Post      
Well, I picked up a tranny at the junk yard for $65 (can't beat that), and put it on the transplant engine. FYI: If you get a fwd tranny, don't expect the awd clutch to work without some grindage. I'm reusing my vr4 clutch as it has less than 3000 miles on it, and when I put the tranny on, I could not figure out why it wouldn't turn over. Well, after three times pulling it off/on, I realized that it was rubbing at the back near the shaft input hole. NOT ANYMORE!!! hehe Grinder fixed that. I'll get some more pix up tomorrow.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 225964 posted 06/09/05 09:42 PM     Remind Me!  Send Private Message   Edit Post      
Well, old engine/tranny is pulled, auto shifter and pedal assy is pulled, and the manual shifter/cables/pedal assy is all installed. It was actually pretty easy to install it all. The hole where the clutch pedal lever goes through, is cutout in the firewall mat, you just have to drill the holes. The hole where the manual cables go through, has punchouts where the cables would be stock. All you have to do is drill where the holes are. I'll get pix up this weekend of what I'm talking about. Now, time to transplant the engine/trans, finish putting the dash pieces in, run the i/c and piping, and the exhaust, and she'll be ready to kill some hondas.
*FYI: the gs does not have the drivers side axle bolted to the block like the vr4. It just goes straight from the hub to the tranny, no carrier. I suppose they put it on the vr4 for the extra hp it produces? I'm gonna go ahead and put vr4 axles in just to be safe.

**Anyone know of issues I may have with the stock GS fuel pump? I guess I can check caps to see if it's the same. I sure don't want to climb under the car to change it.



~Kenneth Brian
"Censorship offends me" ~Author Unknown



Edited by 14u2nV (06/09/05 09:43 PM)

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Pivvay
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Galant VR-4 org Post #: 225966 posted 06/09/05 09:47 PM     Remind Me!  Send Private Message   Edit Post      
Wait did you grind the clutch or the flywheel? Clutches should be interchangable but flywheels are not. Also it's probably not balanced now if you ground a rotating part.
Just want to make sure nothing blows up on ya.

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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 225967 posted 06/09/05 09:53 PM     Remind Me!  Send Private Message   Edit Post      
I ground some of the aluminum of the bell, NOT the clutch. I'm not that dumb/brave. I made sure I didn't take out to much in one spot, so it should hold up wonderfully.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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Pivvay
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Galant VR-4 org Post #: 225969 posted 06/09/05 10:01 PM     Remind Me!  Send Private Message   Edit Post      
ok just wanted to make sure

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joec
or maybe lick the biss
/2000



Galant VR-4 org Post #: 226009 posted 06/10/05 06:09 AM     Remind Me!  Send Private Message   Edit Post      
The drivers side axle attached to the block was only on the AWD (at least for 1G DSMs). The FWD just had the regular axle. I think they changed axle size on the 1G FWD at one point (1992?). Later ones had a thicker/stronger axle -- don't know if they are interchangeable or you need to match the tranny and axles.

Some people were upggrading FWD to use the AWD axle, but I think you needed a spacer/adapter to fit the AWD axle into the FWD tranny.



1991 GVR4 1630/2000 (sold)

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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 226023 posted 06/10/05 07:05 AM     Remind Me!  Send Private Message   Edit Post      
Cool, thanx for the info. I'll double check before I try it. You know why the awd had it bolted to the block?



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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joec
or maybe lick the biss
/2000



Galant VR-4 org Post #: 226030 posted 06/10/05 07:30 AM     Remind Me!  Send Private Message   Edit Post      
I think it was some sort of equal length halfshaft thing to reduce torque steer?

Found it: http://www.wideopenwest.com/~ksmith3289/faq/halfshaft/dsmawdhalfshaftswap.html

p.s. The above info is from Kyle Zingg, who I believe is on this board as BlackHole?



1991 GVR4 1630/2000 (sold)

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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 226039 posted 06/10/05 07:45 AM     Remind Me!  Send Private Message   Edit Post      
Great info. I think I'll just stick with the stock fwd axles for now, and see how they hold up.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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14u2nV
Resident Pedobear


Galant VR-4 org Post #: 235375 posted 07/12/05 08:17 AM     Remind Me!  Send Private Message   Edit Post   
New update: I got the engine/tranny in last night. It's been slow going, since it's been too hot to get motivated to work on it. All I have left is to hook everything up, run the intake and exhaust, and turn the key (oh, and pray).

FYI: I measured the diameter of the FWD shaft where it fits into the tranny, and the AWD shaft at the same place. They are the same diameter, so there should be no fitment problems there.

To get the AUTO shift cable out, you have to drop the exhaust, drop the heat shield and take out three bolts. Easy.

The motor mounts on the engine are interchangeable. The ones in the car don't look to be, due to the fwd only having one crossmember. Also, the AWD tranny mount, will not fit a FWD tranny. Wish I would have known that when I got the tranny, so I could pull the mount then.

I have a ton of pictures. I didn't think loading them all on here would be to fun, so I have a photobucket account, and as soon as I figure out how to link it, I will.



~Kenneth Brian
"Censorship offends me" ~Author Unknown


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