Lesson 1Final assembly checks: torque audit, driveline angle and joint play inspection, exhaust clearance and heat wrap where neededFocus on final checks, like torque review of key bolts, driveline angles, joint play, and exhaust space with heat wrap if needed around the new setup.
Structured torque audit checklistDriveline angle measurement methodsU‑joint play and phasing inspectionExhaust clearance and rattle checksHeat wrap and shield installationLesson 2Shifter installation and linkage setup: console removal, shifter mounting, cable adjustment, detent alignment and bushing lubricationInstall shifter and set linkages or cables, including console take-off, base fitting, alignment, cable tweak, detent check, and lube for good feel.
Console and trim disassembly stepsShifter base alignment and fasteningRod or cable linkage orientationDetent position and gate verificationBushing and pivot lubrication pointsLesson 3Transmission fitment and mounting: input shaft engagement checks, pilot/bearing installation, crossmember and mount torquingPosition and mount the manual gearbox right, check input shaft fit, fit or check pilot bearing, and torque crossmember and mounts for alignment and strength.
Verifying bellhousing to block alignmentInput shaft engagement and endplay checkPilot bearing selection and installationCrossmember positioning and shim choicesMount torque specs and fastener sequenceLesson 4Wiring and ECU/TCU adaptations: fitting neutral/safety switch, reverse lamp wiring, speedometer/tachometer signal checks, immobilizer and TCM reprogramming/blanking strategiesSet up wiring and controls for manual, including neutral safety and reverse lights, speedo and tacho signals, and plans for immobiliser, ECU, TCM coding or blanking.
Neutral safety and clutch switch wiringReverse lamp switch integrationSpeedometer and tachometer signal pathsECU coding for manual configurationTCM removal or reprogramming optionsLesson 5Fluids, bleeding and adjustments: gearbox fill procedures, hydraulic system bleeding, clutch freeplay adjustment, shifting feel setupPick right fluids and fill gearbox, bleed hydraulic clutch, set freeplay, and tweak shift feel for smooth gears and solid selection.
Selecting gearbox oil type and gradeFill level checks and leak inspectionHydraulic clutch bleeding techniquesClutch freeplay and bite point setupTest drive and shift feel refinementLesson 6Clutch system installation: flywheel replacement or machining, clutch disc alignment, torque sequence and rotor runout checksFit clutch system: check or machine flywheel, align disc, torque plate in order, and measure runout to stop chatter and early wear.
Flywheel inspection and resurfacingChoosing bolts and thread treatmentClutch disc alignment tool usePressure plate torque patternRunout measurement and limitsLesson 7Vehicle reception and documentation: photos, VIN, module coding record, pre-conversion test drive checklistReceive vehicle, document state, snap photos, note VIN and modules, and do pre-swap road test for baselines on drive, noise, and codes.
Initial walkaround and photo setRecording VIN, mileage, and optionsScanning and saving module coding dataPre‑conversion road test checklistCustomer concerns and sign‑off formsLesson 8Removal sequence: draining fluids, disconnecting battery, removing automatic transmission, torque converter/flexplate removal, exhaust and crossmember removalSafe order for draining fluids, battery disconnect, auto gearbox and converter removal, flexplate handling, and exhaust/crossmember take-down without harm.
Battery disconnect and safety prepDraining ATF and related fluidsSeparating torque converter from flexplateSupporting and lowering the transmissionExhaust and crossmember removal stepsLesson 9Pedal box fit and clutch actuation setup: installing master cylinder or cable, routing hydraulic lines or cable, reservoir placement and securingFit pedal box and clutch actuation: master or cable fit, pedal ratios, line or cable routing, reservoir spot, and secure against wear.
Pedal box removal and trial fittingMaster cylinder or cable bracketryHydraulic line or cable routing pathsReservoir placement and mountingPedal travel, stop, and switch adjustmentLesson 10Firewall/tunnel and mounting modifications: measuring required clearances, cutting/patching, adding reinforcements and heat shielding if necessaryCheck and mod firewall and tunnel for gearbox space: measure, cut, patch, reinforce, add heat shield, keep structure and seals sound.
Measuring gearbox and shifter envelopeMarking and cutting the tunnel safelyFabricating and welding patch panelsAdding structural reinforcementsSeam sealing, paint, and insulation
