Manual gearbox conversion requirements

[steelroe]

Just completed converting CHris's (fatboyfat7) 5 speeed tip Version R to manual.
If anyone is thinking of doing this and is buying the kit please make sure you have everything listed below.

MANUAL GEARBOX
Abvious one but make sure you also get the following with it. Gear cable mounting bracket. Clutch Fork including the release bearing retainer clip.
Clutch pipe mounting bracket.
The engine mount brackets are the same on the tip and manual boxes so you will already have these.
You also need the engine mounting on top of the box as the tip one is different.

GEAR SELECTOR UNIT AND CABLES
Again an obvious one but make sure you get the gear knob and leather gaitor.

COMPLETE CLUTCH KIT
Do not use a previously fitted clutch and release bearing.

REVERSE LIGHT SWITCH and CONNECTOR
The switch is fitted to the top of the manual box, and you will need the relevant connector cut from a manual wiring harness. Yes you can work around this but it can be messy and possible water ingress afterwards.

CLUTCH/BRAKE PEDAL ASSEMBLY UNIT

38mm HOLE SAW
This is need to bore the hole in the firewall to fitr the clutch servo unit.

CLUTCH SERVO, SLAVE CYLINDER and PIPING
Again make sure the piping and fluid cover is supplied.


All the bolts are usable from the tip box so no prob there.
Note there also may be an issue with the inner CV joints depending on the donor box and the version pof the tip box.
The shafts and outer Joints are all the same no matter which fto you have.

Of course you will need a selection of tools.

[CJ]

Great post Rory, moved to Knowledgebase.

CJ

[Kace]

I came across this article tonight - hadn't seen it before but seems to be a very good guide

http://www.scribd.com/doc/38071418/Fto-how-to-Convert-a-Tip-to-Manual

[ottostreet]

Will a gearbox from a GX transfer to a VR? Or does it have to be a gearbox from a Mivec car as well?

[StewyD32]

Will a gearbox from a GX transfer to a VR? Or does it have to be a gearbox from a Mivec car as well?

As far as i can remember it has to be from a mivec as well as the splints/splits (whatever ya call them) in the drive shaft are different as one set is shorter than the other.
However this can be overcome..... I could be totally taking this out of context. im sure someone will set me right.

When i bought the FTO is have now with the shagged gearbox i was going to get a gearbox of Paul who had a gx but also needed to shaft for this.
Mr gearbox, Mr clutch in finglas (an expert in this who i went to as he is highly recommended wouldn't even bother in trying to change it over so had to scour the earth to get a GPX gearbox for him).

[ottostreet]

Well...crap. I had sourced a manual GX for the job. Crap. Stupid GPXs!

[StewyD32]

There is a thread with a few posts on this somewhere but can't find it for ya. Almost sure of it now.
Also GPX boxes are getting harder to come across now

[StewyD32]

Ok had another trawl through things and the conversations must have been PMs.
But found this :

http://fto-ireland.com/forum/viewtopic.php?f=12&t=12542

[ottostreet]

Cheers, think I'm just gonna have to find a GPX and buy the whole damn thing! :)

[StewyD32]

If you buy it and do it yourself it will work out to be relative.
Cost me about €750 I think if not €800 for mine to be replaced. That's what ya pay to have the only gpx gearbox for sale in Ireland at the time lol.

[goz_83]

Otto,

The ad is 25 days old, but you might call this guy and see if he still has a manual mivec engine/gearbox is available according to the ad. Based in Fermanagh.

http://cars.donedeal.ie/for-sale/cars/3197766

[ottostreet]

No response from them. Out of interest, do any of ye know any gearboxes that require little work to fit? ie. Anything 5/6 speed that will mount straight on, maybe with a change in ECU but very little else work?