240 wagon tranny change ? viable?

[JP]

I'm looking for a 1991~1993 240 wagon with a 5 spd and it would appear
that the vast majority are with auto trans.

How difficult would it be to convert one from auto to 5 spd?

I would need to add a clutch pedal but are the tranny mountings the
same? floor cut-out appears to be the same location too. How about the
engine electronics? Any differences?

Estimates as to the time needed to do?

Any thoughts, comments and ideas are welcome.

TIA

Anyone in the NorCal area have a such a wagon with low miles to sell ?

 

[James Sweet]

I'm looking for a 1991~1993 240 wagon with a 5 spd and it would appear
that the vast majority are with auto trans.

How difficult would it be to convert one from auto to 5 spd?

I would need to add a clutch pedal but are the tranny mountings the
same? floor cut-out appears to be the same location too. How about the
engine electronics? Any differences?

Estimates as to the time needed to do?

Any thoughts, comments and ideas are welcome.

I've done a few of these conversions and just picked up the parts yesterday
to do another. Here's what you need, most all of these parts can come from
anything '79-'93, but if you want the true 5 speed M47 you'll need to find
an '87 or later:

Transmission

Driveshaft

Pedal bracket (has clutch and brake pedals)

Flywheel

Pilot bearing and clip

Clutch cable

Clutch kit

Shifter/shift boot assembly

Overdrive wiring (M-46 only)

I recommend buying a new clutch kit, cable and pilot bearing, the rest can
come from a junkyard. New pedal pads is a nice touch as well. You may have
to drill a hole for the clutch cable, some cars have it already with a
rubber plug, others don't. Otherwise the job is pretty much remove the
automatic and related hardware and install the manual. I've paid anywhere
from $125-$300 for all the nessesary parts, but that depends on location.

If you get stuck feel free to email me, first one I did took 3 or 4 days,
the last one was almost finished in a day, these cars are really wonderfully
simple to work on.

 

[Steve Rogers]

One thing you might have forgotten about is that there are differences
in the rear end ratios between the automatics and the manuals. Unless
you are prepared to use a compromised rear end ratio in the manual
conversion, you might want to consider the rear end in the list of parts
to obtain from the manual transmission donor car.

 

[James Sweet]

One thing you might have forgotten about is that there are differences
in the rear end ratios between the automatics and the manuals. Unless
you are prepared to use a compromised rear end ratio in the manual
conversion, you might want to consider the rear end in the list of parts
to obtain from the manual transmission donor car.

The rear end used in the automatic cars is the same as was used in the
manual equipped turbos, the gearing is a bit shorter but this doesn't cause
a problem, you get a bit more torque at the expense of slightly higher RPM
on the highway. When I did the conversion on my mom's '86 wagon the fuel
economy improved noticeably and she hasn't complained about the extra few
hundred RPM's on the freeway.