Manual Conversion Help

[robbyj]

Hey guys, just a query

What is actually needed/involved in a manual conversion.

Gearbox
Manual ECU
...

And what is the rough cost including labor.

I know a few have done it in the build threads, just want a bit of discussion here

Thanks.

[Day-mow]

Alot of patience. Add that to the list.

[Beer Baron]

Gearbox
Bellhousing.
Clutch fork
Clutch cable
Pedal box
Pcm
Tailshaft
A ford dealership
Shifter
Flywheel
New clutch kit
Spigot bearing
Oil

Labor ? I'll tell you when I've done mine soon ;)

[robbyj]

Thanks mate, checked ya build thread but nothing in there?

How did you go about sourcing the parts?

[Beer Baron]

Still sourcing parts, Just waiting on FTG to get back to me. As soon as i get it im dropping the auto out.

Will have to ring him on Monday as PM's take too long.

[jaydenxr6]

mate just did one on my au II xr6 ute. its not hard believe me i did it on the floor of my garage patience and help from strong mates cause the autos weigh a tonne! and just aligning the manual into the clutch if you need help im from around eltham area i have clutch aligning tool and a good contact that helped me through alot of my troubles. Things like smartlock reprogramming to the new manual ECU (engine control unit) a PCM is for an auto so dont get them mixed up manual cars doo not take PCM's. anyway mine runs great goes like all hell now and im still running automatic computer for time being until i can get around to taking it to my mate at ford to program smartlock to the new manual computer. good luck champ dont let people talk you out of it makes driving your falcon so much more fun and will increase resale value! just ask man if you have any issues!! once again good luck

[Day-mow]

Gotta agree with the above statement. Although I didnt convert mine it sure as heck is great to drive.*







* disclaimer. Unless your in peak hour traffic then you hate life

[robbyj]

Thanks jayden, ill certainly keep that in mind.
Can i ask what was the rough cost?

[robbyj]

Originally Posted by Day-mow

Gotta agree with the above statement. Although I didnt convert mine it sure as heck is great to drive.*

* disclaimer. Unless your in peak hour traffic then you hate life

Peak hour traffic in my country town is 4 cars stuck behind a tractor. So not an issue. But as you say, you start hating on life in peak hour.

But it will make the car so much more enjoyable to drive.

[chrispie123]

ecu is not needed i recently did mine and all you need is to put a 6.8k resistor in the loom that used to connect to trans on the wire colors for trans temp as thermos run flat out unless you do this bypass neutral swith by joining wires together and she is sweet

[Day-mow]

Originally Posted by bobuleh

Peak hour traffic in my country town is 4 cars stuck behind a tractor. So not an issue. But as you say, you start hating on life in peak hour.

But it will make the car so much more enjoyable to drive.

hahahaha yes valid. i used to live in one of those towns as well.
while your at it. maybe get a HD clutch saves doing it again anytime soon. up to you.

[bartsau]

The one thing I would say is get a HD clutch if you plan on giving it a hard time at all such as drags, etc. The standard clutch is just not up to the job nearly as well. As for what you need and prices I have covered it a fair bit in my build thread (link below in sig) and there are a couple of others from a while ago with some more info.

You will simply love it!!!

Rhys

[Beer Baron]

I priced up some clutches recently.

$250 for a genuine ford kit.
$275 for a Standard Exedy kit.

[robbyj]

Originally Posted by bartsau

As for what you need and prices I have covered it a fair bit in my build thread (link below in sig) and there are a couple of others from a while ago with some more info.

You will simply love it!!!

Rhys

Thats in my price range, which was what i was hoping, how did you source the parts?

[Day-mow]

HD exeedy clutch and spigot bearing cost me $400.

[Beer Baron]

Just cost me $1150 for the whole manual conversion kit from FTG.

[robbyj]

Originally Posted by Beer Baron

Just cost me $1150 for the whole manual conversion kit from FTG.

Cool, thanks mate, some serious thinking to do now

[bartsau]

Excedy HD clutch / spigot bearing and machined flywheel cost me about $475 I think from memory.

As for sourcing parts I know there are some wreckers that you can get the stuff through but I got the parts by buying a written of Manual Ute. I found this to be the cheapest way. But it did involve time and effort on my part which was not taken into account cost wise. If I take the time I spent sourcing the parts I would have been better off buying it all at just about any price.


Rhys.

[au adam]

Originally Posted by Day-mow

hahahaha yes valid. i used to live in one of those towns as well.
while your at it. maybe get a HD clutch saves doing it again anytime soon. up to you.

Dont do a heavy duty clutch,just adds to the stress on the firewall and the cracks will start.
Mine just cost me $1600 to put right.

[Beer Baron]

Originally Posted by au adam

Dont do a heavy duty clutch,just adds to the stress on the firewall and the cracks will start.
Mine just cost me $1600 to put right.

What did they do to fix it and do you have pictures ?

Im going an Exedy standard clutch, I dont plan on doing skids or drags.

[Day-mow]

Originally Posted by au adam

Dont do a heavy duty clutch,just adds to the stress on the firewall and the cracks will start.
Mine just cost me $1600 to put right.

we'll mines not been cracked yet and i kick it pretty hard.
also i've herd that if you install them right they dont crack

[au adam]

Originally Posted by Beer Baron

What did they do to fix it and do you have pictures ?

Im going an Exedy standard clutch, I dont plan on doing skids or drags.

I had the pedal assembly replaced(they bend)
Fire wall re-welded and reinforced with steel plate.
New standard clutch
New clutch cable
New fluid in the box.
$1600
Car went from a dog to change gears to a piece of ****.
My Patrol had a light clutch(hydrolic) and the AU is now lighter than that.

[au adam]

Originally Posted by Day-mow

we'll mines not been cracked yet and i kick it pretty hard.
also i've herd that if you install them right they dont crack

Thats great for you but have a bit of a search on here and you will see the issues you could face.

[Beer Baron]

I just finished converting my au2 to manual today and it took me 9 hours to do it with a small trolley jack, 2 stands, 1 old tyre, lots of swearing at the auto and 2 mates.

The hardest part was the top bolt on the starter motor, Trying to not drop the auto on the concrete and putting the manual pedal box in.

It drives fine with the auto ecu but the idle is sometimes low and sometimes high. The fans go all the time and takes about 40 mins to reach operating temp.

Des ;)

[robbyj]

Nice work mate, good to hear it all went well

[jaydenxr6]

fantastic mate! sorry i have been lazy i dont always go on the threads but happy to help where i can! my whole job including just recently getting manual ecu programmed about $1000 for the lot that was me doing it! so defanantly well worth it love driving it and with the computer done my fuel consuption is better and runs like an absolute dream!!!

[Legit290]

still waiting for your tune results mate

[chrispie123]

boubleh you can stop the fans from running flat out by cutting t wires that used to go to trans in big plug and put a 6.8k resistor in its path this is just a trans temp bypass as ecu thinks the trans is hot hence running fans flat out

[Beer Baron]

Just got my ecu programmed to the car today, Drives much better and is easy to take off from a stop.

[bartsau]

Great news to hear there is now another manual AU about!! Glad it went well. Now you can really enjoy another side of the AU falcon ;)