Auto to 5 Speed Manual Conversion
or .. so, you'd like to convert an auto to a manual?
by Stuart Mollart

Yep that's what I said to myself. So after quite a bit research I decided to buy another 928 a 1980 928S 5 speed and transfer the whole drive train (less the motor) into my car, sounds easy... HA!

Info about auto bodies.

If your car is pre 1986* you have the clutch master cylinder mount on the firewall. This is good - as all you have to do is drill out the holes that were covered up. If your car is post 1986* then you don't have the mount on the firewall, and you must do a firewall transplant - cut old one from manual donor and weld into the auto body - well I'm not going to get into that process - check out
www.kondratyev.com/porsche/convertible/clutch_linkage.htm

*RHD cars - don't hold me to these dates -  due to variations in production runs etc. - check the firewall on your 928.

What's required in parts?

• Flywheel

• Pilot bearing for rear of crank

• Clutch assembly inc. clutch fork

• Bell-housing

• Torque tube

• 5 speed box

• Cross member

• Gear shifter & boot, facia etc.

• Clutch master cylinder with connection rod

• Clutch slave cylinder with push rod & hydraulic line/flex hose

• Clutch/brake pedal assembly

• Micro switch for cruise control, rubber stopper for clutch pedal.

• Reverse switch/speedo pickup wiring

• Wire link to bypass auto lockout relay
  

The Process.

• Remove the motor
  Yes! You will find it a whole lot easier to do - well I did.
  
  

• Remove auto trans
  and torque tube - I did this in one process.
  
  

• Modify firewall
  for clutch master cylinder mount.
  
  

• Cut auto shifter mount
  from trans tunnel.
  
  

• Transfer rear suspension
  onto manual cross-member.
  
  

• Install gearbox
  and torque tube.
  
  

• Install rear suspension
  
  

• Change flywheel/clutch - soon!
  
  

• Mount clutch
  brake pedals.
  
  

• Wiring.
  
  

• Top up diff/gearbox
  with the correct oil
  
  

• Get a 4 wheel alignment
  the rear end now needs re-aligning.
  
  

• Testing!
  I will have to wait a couple more weeks - I'm rebuilding my motor at the moment.
  
  

Comments.

Well what a fun job it's been, it's not a difficult job. If you have the space, tools and patience.

Cost: about $7,500(AUD) - most of that's the cost of the car and a handful of minor bits and pieces. Second hand parts come to about the same cost - if you can find them.

Time: that's a hard one - estimated 30 hours of no mucking about - otherwise about a weeks work.

Can you see the difference?

Contact me: stuart at ozebiz dot com dot au

top | remove auto trans | modify firewall
cut shifter mount | transfer rear suspension | install gearbox
install rear suspension | mount clutch | wiring | back

© Copyright 2006 Leonard Zech