Swapping from automatic to manual transmission in a G35 enhances driver engagement and performance․ Key components like the CD009 transmission, flywheel, and clutch kit are essential for success․
1․1 Overview of the Swap Process
The G35 automatic-to-manual swap involves replacing the automatic transmission with a manual unit, such as the CD009 or CD00A․ Key steps include removing the automatic transmission, installing the manual transmission, and adapting the clutch system․ Additional modifications like ECU reflash, wiring harness updates, and pedal assembly installation are necessary for proper functionality․ Safety and precision are critical throughout the process․
1․2 Benefits of Converting to Manual Transmission
Converting to a manual transmission enhances fuel efficiency and driver control, offering a more engaging driving experience․ It also simplifies maintenance with fewer components, potentially lowering long-term costs․ Additionally, manual transmissions are often preferred by enthusiasts, which can boost resale value․ However, the initial investment and learning curve for clutch operation are important considerations․
Key Components Required for the Swap
The manual transmission, clutch kit, flywheel, and pedal assembly are essential․ Additional components include hydraulic systems, mounting hardware, and drivetrain adapters to ensure compatibility and smooth operation․
2․1 Manual Transmission Options (CD009/CD00A)
The CD009 and CD00A are popular manual transmission choices for the G35 swap․ The CD009 is a widely used, reliable option with a strong gear set, while the CD00A offers improved internals for added durability․ Both transmissions are compatible with the G35’s engine and chassis, making them ideal for achieving a smooth and responsive manual drivetrain configuration․
2․2 Clutch Kit and Flywheel
A complete clutch kit, including the pressure plate, disc, and throw-out bearing, is essential for the swap․ A 5-speed flywheel is required, as automatic transmission flywheels are incompatible․ Upgrading to a lightweight or performance-oriented flywheel can enhance drivetrain efficiency․ Ensure all components are new and compatible with the manual transmission to guarantee smooth engagement and reliable performance․
2․3 Pedal Assembly and Hydraulic Components
The manual transmission requires a clutch pedal assembly, sourced from a donor car or aftermarket supplier․ Hydraulic components, including the master and slave cylinders, must be installed to actuate the clutch․ Ensure proper alignment and bleeding of the hydraulic system for consistent pedal feel and reliable clutch engagement․ These components are crucial for smooth manual operation․
Preparing for the Swap
Preparation involves gathering tools, setting up a clean workspace, and ensuring safety․ Protective gear, proper lighting, and a detailed parts list are essential for efficiency and safety․
3․1 Tools and Workspace Setup
A well-organized workspace and the right tools are crucial for a smooth G35 automatic to manual swap․ Essential tools include wrenches, sockets, pliers, a torque wrench, and a transmission jack․ Ensure a clean, flat work area with proper lighting․ Use jack stands for safety and a drain pan for fluid collection․ Organize all parts and tools beforehand to maintain efficiency and avoid losing components during the process․
3․2 Safety Precautions
Ensure a safe working environment by wearing protective gear like gloves and safety glasses․ Use jack stands to secure the vehicle and avoid working under an unsupported car․ Disconnect the battery to prevent electrical hazards․ Keep a fire extinguisher nearby and work in a well-ventilated area․ Be cautious of hot engine components and sharp edges․ Always follow proper lifting techniques to avoid injury․
Removing the Automatic Transmission
Disconnect electrical and hydraulic connections carefully․ Use appropriate tools to remove bolts and mounts․ Support the transmission securely before lifting it out of the vehicle․
4․1 Disconnecting Electrical and Hydraulic Connections
Begin by identifying and disconnecting the electrical connectors linked to the automatic transmission, such as the transmission control module and speed sensors․ Next, carefully disconnect the hydraulic lines connected to the torque converter and transmission cooler․ Properly cap these lines to prevent fluid leakage and contamination․ Ensure all connections are safely removed to avoid damage during transmission extraction․
4․2 Physical Removal of the Automatic Transmission
With all connections disconnected, use a transmission jack to carefully lift and support the automatic transmission․ Remove the transmission mounts and any remaining bolts securing it to the engine and chassis․ Gently maneuver the transmission out of the vehicle, ensuring the torque converter remains attached․ Be cautious of any components that may fall during removal․ Drain transmission fluid beforehand to prevent spills․
Installing the Manual Transmission
Mount the manual transmission to the engine using appropriate bolts and gaskets․ Ensure proper alignment with the bellhousing and secure it firmly․ Connect the drivetrain components, including the driveshaft, to the transmission output shaft․ Verify all connections are tight and properly aligned before proceeding․
5․1 Mounting the Manual Transmission
Mounting the manual transmission begins with aligning it to the engine and bellhousing․ Secure it using bolts and gaskets, ensuring a leak-free seal․ Proper alignment is crucial to prevent damage and ensure smooth operation․ Once mounted, double-check all connections and torque specifications to guarantee a secure and accurate installation․
5․2 Connecting the Drivetrain
After mounting the manual transmission, install the driveshaft and connect it to the transmission output shaft․ Ensure proper alignment and secure the drivetrain components with appropriate bolts․ Check for any leaks or misalignments․ Test-fit all connections to confirm they are snug and functioning correctly before finalizing the installation․
Wiring and Electrical Modifications
Wiring and electrical modifications are crucial for a smooth manual swap․ Rewire and adapt the harness to accommodate the manual transmission setup, ensuring compatibility with new components․ Consult a professional to avoid electrical issues during the process․
6․1 ECU Reflash and Wiring Harness Adaptation
ECU reflash is essential for manual transmission recognition, ensuring smooth communication between engine and gearbox․ The wiring harness must be adapted to accommodate the clutch pedal and reverse light switch․ Proper installation and testing are critical to prevent electrical issues, such as engine stalling or incorrect gear shifts․ Consult a professional if inexperienced in wiring to avoid potential problems․
6․2 Installing Aftermarket Electronics
Aftermarket electronics like shift lights and engine management units enhance the manual swap experience․ These components improve shifting precision and engine performance․ Ensure compatibility with your G35’s system and install them correctly to avoid electrical issues․ Professional installation is recommended for optimal functionality and reliability․ These upgrades complement the manual transmission, offering better control and driving satisfaction․
Clutch and Flywheel Installation
Installing the clutch and flywheel ensures smooth manual transmission operation․ Proper alignment and secure mounting are crucial for optimal performance and durability․
7․1 Installing the Flywheel
Begin by ensuring the engine is secure․ Remove the automatic transmission flex plate․ Clean the crankshaft area thoroughly․ Apply a thin layer of high-temperature lubricant to the crankshaft pilot bearing․ Align the flywheel with the crankshaft, ensuring it seats properly․ Tighten the flywheel bolts in a star pattern to the specified torque to prevent warping the flywheel surface․
7․2 Setting Up the Clutch System
Install the clutch kit, ensuring the clutch disc is centered and aligned with the pressure plate․ Secure the pressure plate using the provided bolts, tightening evenly in a star pattern․ Connect the hydraulic clutch line to the slave cylinder and bleed the system to remove air bubbles․ Ensure proper clutch pedal travel and adjust the clutch master cylinder as needed for smooth engagement․
Pedals and Hydraulic System Setup
Install the clutch pedal assembly, master cylinder, and slave cylinder․ Connect hydraulic lines and bleed the system to ensure proper clutch engagement and smooth operation․
8․1 Installing the Clutch Pedal
Mount the clutch pedal assembly, ensuring proper alignment with the master cylinder․ Secure the pedal using the provided hardware․ Adjust the pedal height and free play for optimal driver comfort and precise control․ Confirm the pedal operates smoothly, engaging the clutch fully when pressed․ Ensure all connections are tight and properly routed․
8․2 Bleeding the Hydraulic System
Bleeding the clutch hydraulic system ensures air-free fluid flow․ Start by filling the master cylinder reservoir with clutch fluid․ Attach a bleeder hose to the slave cylinder port, then pump the pedal several times to expel air․ Tighten the port and repeat until fluid flows without bubbles․ This ensures smooth clutch engagement and optimal system performance․
Chassis and Drivetrain Modifications
Modifying the chassis and drivetrain ensures compatibility with the manual transmission․ Key adjustments include updating the transmission cross-member and rear differential for proper alignment and performance․
9․1 Transmission Cross-Member Modification
Modifying the transmission cross-member is essential for a manual swap․ The automatic transmission cross-member must be altered to accommodate the manual transmission’s mounting points, ensuring proper clearance and alignment․ This step prevents interference and guarantees compatibility․ Precise measurement and welding are required for a secure fit․ Failure to modify the cross-member can lead to drivetrain misalignment and potential damage․
9․2 Updating the Rear Differential
Updating the rear differential is crucial for compatibility with the manual transmission․ The manual transmission may require a different gear ratio or limited-slip differential for optimal performance․ Ensure the rear differential matches the new transmission’s specifications to maintain proper drivetrain harmony and traction․ This step is vital for achieving the desired handling and power delivery after the swap․
Testing and Troubleshooting
After installation, conduct a test drive to ensure smooth operation․ Check for proper clutch engagement and gear shifting․ Troubleshoot common issues like leaks or misalignment promptly․
10․1 Initial Test Drive
Begin with a slow, controlled drive to assess clutch feel and gear engagement․ Ensure smooth transitions between gears and proper clutch release․ Check for any unusual noises or vibrations․ Monitor the hydraulic system for leaks or pressure issues․ Incrementally increase speed, testing acceleration and deceleration․ Pay attention to any hesitation or slipping during shifts․
10․2 Diagnosing Common Issues
Common issues after a swap include improper clutch engagement, hydraulic leaks, or misaligned components․ Check for air in the hydraulic system, which can cause a spongy pedal․ Verify wiring connections and ensure the ECU is properly reflashed․ Listen for grinding noises during shifts, indicating misalignment․ Systematically troubleshoot each system, starting with the clutch and drivetrain, to identify and resolve issues efficiently․