Automatic To Manual Transmission swap project.

Post by **Roadhog** » Jun Thu 28, 2007 9:43 pm

Well I was able to source myself a transmission and other stuff...

I will post a project here with pics and everything.

So here is the rundown so far.

The transmission I am getting has ~100k miles on it, and was fully rebuilt and has only 5000 miles on the rebuild.

Here is a sneak peak of all the stuff it comes with and the mess I am in for

1. Pedal Cluster
2. Shift Box and Cables with selector shaft and connecting hardware
3. Clutch Master cylinder
4. Clutch Slave Cylinder
5. Line between Clutch slave and master
6. Master cylinder mounting bracket, specify abs or non abs
7. Karmann shifter trim plate with OEM boot and shift knob
8. o2a VR6 Transmission with linkage and reverse light sender
9. front motor mount bracket
10. 5 speed starter

And some other stuff like nuts, bolts, lines and what not.

Cost for the swap with above parts- $650

The clutch and flywheel I will have to get in a couple weeks when funds permit it.

Post by **Roadhog** » Jun Sat 30, 2007 5:02 pm

And its off... Doing the Head Gasket too and some other things...

Pics:

Got the front off and the radiator out.

What a mess.

Removed the upper intake manifold.

Some parts.

Worn and broken timing chain tensioner.

Currently.

Post by **kompressorgolf** » Jun Sat 30, 2007 5:32 pm

nice! good to see some others balls deep in projects! that car will be twice as fun with a good ole fashioned mani trans!! oh yeah, so what about that head gasket spacer???

Post by **Roadhog** » Jun Sat 30, 2007 7:04 pm

kompressorgolf wrote:nice! good to see some others balls deep in projects! that car will be twice as fun with a good ole fashioned mani trans!! oh yeah, so what about that head gasket spacer???

lol neva.. ill go all motor before fi.

But, just took the head bolts out and broke the head free...

The bolts were a fucking workout.. omg. im tired.

The head took a come along strapped to the roof to break free...

EDIT: my back hurts... $:\$

Post by **kompressorgolf** » Jun Sat 30, 2007 7:27 pm

somone has been into that motor before then and way over torqued those head studs..... they shouldnt be that bad to break free unless your using a very short ratchet i use a long breaker bar and even then the head should come loose from the block with little more than a wiggle! hope you got u a bently!

p.s. if you got those parts, do you know where i can find a VR6 corrado K-frame???

Post by **Roadhog** » Jun Sat 30, 2007 8:33 pm

kompressorgolf wrote:somone has been into that motor before then and way over torqued those head studs..... they shouldnt be that bad to break free unless your using a very short ratchet i use a long breaker bar and even then the head should come loose from the block with little more than a wiggle! hope you got u a bently!

p.s. if you got those parts, do you know where i can find a VR6 corrado K-frame???

You might want to ask www.corradoparts.com

I only had a normal ratchet to break them free.

Post by **Roadhog** » Jun Sat 30, 2007 8:36 pm

Well I got the head yanked off. I can see where the gasket was blown around cylinder 1. You can still see the cross hatching/ hone marks in the cylinder walls! None of the piston have been cleaned at all when I took these pics.

Clean Pistons and dirty #1

Head

Another pic of the block.

Post by **kompressorgolf** » Jun Sat 30, 2007 11:57 pm

i just took the head off my 16v and for pure science did it with a ratchet, one hand and a good yank per and they were out and the head lifted smoothly that motor looks good and clean tho

Post by **Roadhog** » Jul Sun 01, 2007 10:38 am

kompressorgolf wrote:i just took the head off my 16v and for pure science did it with a ratchet, one hand and a good yank per and they were out and the head lifted smoothly that motor looks good and clean tho

I think they are factory torqued. You have to torque them to ~55 ft lbs, then a 180 turn, and 2, 1/4 turns.

Post by **Roadhog** » Jul Tue 10, 2007 5:36 pm

Got some parts and a head back from the machine shop!

MK4 HG and some other stuff..