TA22 Manual Conversion Write-Up

[kugzs]

here is a write-up for a ta22 manual conversion. I did this a few months ago with craigD. I never bothered to put it up because towards the end of the write up (when it was getting dark, and we were getting dirty, tired and frustrated) i took fewer and fewer pics. But i may as well put it up if it helps anyone.

Feel free to correct me/add more tips and pics. I will then edit my original post.

Here it goes;

The order of steps, in some cases, will not be important, however, this is simply the order that we did things.

1. Press out throwout bearing.
2. Disconnect the negative from the battery.
3. Remove the blanking plate on the firewall.
http://img316.imageshack.us/img316/6...tatchedzg9.jpg

4. Loosen the bolts on the steering column to lower the steering wheel. These are the three bolts located on the underside of the steering column on the leftish.
http://img460.imageshack.us/img460/1...mnboltsrf8.jpg

5. Once the steering column has been lowered, you will have better access to the pedal box. The next step is to remove the five 12mm bolts from the auto pedal box.
6. Remove the centre console.
http://img459.imageshack.us/img459/7872/autonobhf0.jpg
http://img459.imageshack.us/img459/7...escrewsdy7.jpg
http://img507.imageshack.us/img507/3...consoledw7.jpg
http://img507.imageshack.us/img507/1...consolevc1.jpg

7. Reconnect the manual pedal box (or change the pedals etc from the manual pedal box to the auto one). A tip may be to leave the clutch pedal out until the new pedal box is bolted in.
http://img357.imageshack.us/img357/5079/pedalssu8.jpg

8. Drain the auto fluid
http://img314.imageshack.us/img314/2530/drainingdv1.jpg

9. Disconnect the auto-tailshaft
http://img441.imageshack.us/img441/5...ilshaftdk4.jpg

10. Disconnect the oil cooler from in front of the radiator. Also remove the attatched lines but be careful, these will be full of oil. Trust me it makes the rest of the conversion a whole lot cleaner if the area under and around the car is not covered in oil.
http://img441.imageshack.us/img441/4...lcoolerqy2.jpg

11. Disconnect the kick down cable.
http://img124.imageshack.us/img124/6...wncablerc7.jpg

12. Unbolt starter motor and torque converter. Here is where we had a bit of problems as one of the bolts on the torque converter had been rounded off. Nothing the purchase of some power tools couldn’t fix.


13. Unbolt the gearbox but leave one bolt in (loosely) for safety reasons.

14. Unbolt gearbox crossmember
http://img112.imageshack.us/img112/7...smemberco4.jpg

15. Remove speedo cable.

16. Remove gearbox.

17. Remove flex plate

18. Insert spigot.

19. Put in flywheel. It is a good idea to use threadlocker. Here is where we ran into another problem. When tightening the bolts on the flywheel one of the head snapped off. But about an hour later (after having acquired some more power tools) we were back on the right track.

20. Put on the clutch/pressure plate and use a clutch tool to align. Then reconnect everything and bolt up.

21. Change unis and put crossmember and tailshaft back in.

22 Enjoy

Sorry again about the lack of pics in the later stages

[kugzs]

shit just realised i left out parts about the clutch slave and master. Will add in later.

[Dale]

You also have to cut more out of the shifter hole at the firewall end, and put a plate in at the lower end to prevent dirt, water etc getting in under there

[kugzs]

true, i will post pics of the cutting required soon.