Second automatic to manual swap completed

[Belenus]

First off, I'd like to thank Stan for offering to help with the swap. I just got too excited to not start without him. Also, just wanted to let you know why I haven't really been active on the forum and missed the Letchworth drive-- I now have a 5 speed supercharged miata!

The reason for starting this thread is so I can do a full write-up of the swap (with over 50 pictures!!!) for anyone on this forum to possibly learn/enjoy and to link over on miata.net. I will be posting the build later on today so stay posted. I suppose I'll also shoot a couple videos as well.

Colin

And now the good stuff...

It all started Sunday night after an autocross. The first thing was to get the car high enough. It takes forever but slow and steady is the only safe way to do it.



Next, the shifter assembly for the automatic came out.



Master cylinder blanking plate came out next



Next up were the pedal assemblies. Do yourself a favor and remove the driver side seat.


These get unbolted, but this is one of the hardest parts IMHO because the steering column needs to be unbolted and dropped. Then the clamp holding the steering column the the steering shaft coming into the car needs to be removed, and the steering column slid out. Out comes the old and in with the new.

After the gas and brake assembly is in, the clutch can go in. There will be some control boxes to un-clip, but just a bolt-in affair after that.


Then the master cylinder


If you don't have a good workshop manual at this point, it's time to invest in one. The general disassembly and re-assembly is as follows (but refer to manual for specifics)-

1. Remove exhaust at the header. Much easier to do in two pieces.


2. Remove the drive shaft.

3. Remove wiring harness from the PPF and the ground wire. Then remove the Power Plant Frame (PPF)- make sure to have a jack supporting the tailshaft of the tranny


4. Disconnect cooler lines, speedo cable, wiring harnesses, etc.

5. Loosen the nuts holding the torque converter to the drive plate.


6. Loosen and remove the starter bolts, then LOOSEN the bell housing bolts.


7. Get a jack with some wood and a friend to get the tranny out. It's heavy!!

8. Remove drive plate and adapter plate. Should also replace front tranny seal.


9. Put the clutch in. If there was one thing I made sure to torque correctly, it was the flywheel/all clutch bolts. Buy or borrow a torque wrench!!


10. I cut the two harnesses from the auto tranny and spliced them into the two switches on the manual. You'll need the blue connector and the black one with the thick wire. Blue is reverse lights, black is the automatic starter inhibitor.


11. In with the tranny. Again, two people is optimal. I did it by myself and wouldn't do it again!


12. Tighten bell housing bolts and starter bolts.

13. In with the PPF. The auto and manual PPF's are different.


14. In with the drive shaft.

15. Put the slave cylinder on. Also, you can put the clutch lines in as well.


16. Put the exhaust back on.

17. Put the interior back together. Put all shift boots on, check to make sure the starter engages when the car is in neutral and the reverse lights work.

All done


18. Bleed the clutch and make sure everything is put back together. Also, make sure there are no tools lurking under the hood or wherever.

19. Test drive!

Tips:

-Install slave cylinder and the shifter after the transmission is in the car
-Have the wires for the two switches ready to go before the transmission goes in
-Soak bolts in penetrating oil before removal

The results:

I have been driving my car for a few days now and there are no problems. The only thing I have noticed the idle is a bit unstable, and the revs hang a bit when you shift. Other than that, everything works just fine. Give yourself a big pat on the back and enjoy.

All pictures that were taken

Miata.net tranny swap write-up

[icantthink4155]

What's your aunt think?

[JCruiza120]

Congratulations!!! How much faster does it feel with the stick?

[Dave P]

i want pics of the supercharger

[Belenus]

Originally Posted by icantthink4155

What's your aunt think?

She was pretty blown away when I told her I had started, then when I called her up on Friday to tell her it was done. And the fact I did it almost completely solo -end brag-.

[alexo35]

I thought you were going to have it done? Nice work. Hopefully its not too much faster.
--Alex

[Belenus]

Originally Posted by JCruiza120

Congratulations!!! How much faster does it feel with the stick?

It feels so much faster with the 5 speed and there's sooo much torque it's not even funny. I've already gone too fast with it (don't worry, only like 80), but I haven't even done a WOT run. Next is the diff, then a timing belt/water pump. Can't wait to go back up for another event with you guys. I'm hoping to make it up there at least a couple more times before the weather turns crappy.


"i want pics of the supercharger"

Here ya go

Crappy quality but this is after the swap. Also see my sig.

[Dave P]

nice...what kit did you get and how much boost are you running, and which charger is that?

[Belenus]

Originally Posted by Dave P

nice...what kit did you get and how much boost are you running, and which charger is that?

This is a Sebring kit, which was the predecessor to the Jackson Racing kit. With the MSD timing box, I'm running 8 psi of boost. I believe the kit uses the Eaton M45 supercharger. I'm probably making no more than 160 at the rear wheels.

[longuyen88]

Congrats!