G35 Auto to Manual Swap⁚ A Comprehensive Guide
This guide details converting your Infiniti G35 from automatic to manual transmission. It covers necessary parts, transmission installation, clutch system integration, wiring harness modifications, interior adjustments, and post-installation checks. Expect challenges and budget accordingly; sourcing a donor car may be necessary.
Necessary Parts and Components
A successful G35 automatic-to-manual transmission swap necessitates a comprehensive parts list. Beyond the obvious manual transmission itself (CD009 is a common choice, though CD00A is a newer option), you’ll need a clutch kit (including pressure plate, disc, and throw-out bearing), a flywheel, and the appropriate flywheel bolts. The clutch pedal assembly, including the master and slave cylinders, along with the necessary clutch line, is crucial. Don’t forget the manual brake pedal and any related hardware if your donor vehicle doesn’t have them. You’ll also require a driveshaft compatible with the manual transmission, and possibly new axles depending on the donor car’s specifications. Consider the need for a new pilot bearing; the automatic’s pilot bearing might not be suitable. The shifter assembly, including the shift knob and linkage components, is needed to complete the drivetrain. Finally, remember the necessary transmission fluid. A detailed checklist comparing your specific G35 model against the donor car’s parts is essential to avoid unforeseen complications.
Transmission and Drivetrain
The heart of the G35 auto-to-manual swap is the transmission itself. Common choices include the CD009 or the newer CD00A, both offering improved synchronizers compared to earlier versions. Ensure compatibility with your specific G35 year and model. Installation requires careful attention to detail, including proper alignment and torque specifications for all bolts. The flywheel, a crucial component transferring engine power to the transmission, must be correctly installed and torqued. The driveshaft, connecting the transmission to the rear differential, needs to be compatible with the manual transmission; a direct swap from a donor car is often the easiest approach. Consider the differential ratio; while some suggest keeping the automatic differential, a manual transmission may benefit from a different ratio depending on your driving preferences and modifications. Remember, the transmission’s mounting points and associated hardware might need adjustment or replacement to ensure a secure fit within the chassis. A professional alignment and thorough inspection of all drivetrain components after installation are highly recommended.
Clutch System and Pedals
The clutch system is paramount for a successful G35 manual conversion. This involves replacing the automatic transmission’s components with a complete manual clutch assembly. This includes a new clutch kit (pressure plate, clutch disc, throwout bearing), a new flywheel (possibly requiring resurfacing), and the necessary hardware like flywheel bolts. The clutch pedal assembly, sourced from a donor manual G35, needs careful installation, ensuring proper linkage and adjustment for smooth engagement and disengagement. The clutch master and slave cylinders, responsible for hydraulic actuation of the clutch, are crucial; bleeding the clutch hydraulic system thoroughly is essential to eliminate air bubbles and ensure proper clutch operation. Consider the condition of the clutch line; replacing it is often advisable to prevent leaks and maintain optimal hydraulic pressure. Installation requires precision; incorrect adjustment can lead to clutch slippage or difficulty shifting. The brake pedal may also need adjustments to account for the added clutch pedal. Remember that using quality components from a reputable supplier is essential for reliable clutch performance and longevity. Improper installation can result in significant damage to the transmission.
Wiring Harness and ECU
The wiring harness and ECU (Engine Control Unit) modifications are critical for a functional manual transmission swap in your G35. The automatic transmission’s wiring harness needs to be replaced or extensively modified to accommodate the manual transmission’s components. This involves removing unnecessary wiring related to the automatic transmission’s components like the torque converter and electronic controls. The manual transmission’s wiring harness will need to be integrated into the existing vehicle harness. This may require splicing, connecting, and potentially adding new wires to control the clutch safety switch, reverse lights, and other manual transmission-specific circuits. The ECU plays a crucial role, as the automatic transmission’s ECU is not compatible with a manual setup. You’ll likely need a manual transmission ECU, either from a donor car or reprogrammed to accommodate the swap. This step requires a thorough understanding of automotive electrical systems; Incorrect wiring can lead to malfunctions, engine damage, or even a non-starting vehicle. Consult detailed wiring diagrams and seek help from experienced mechanics if needed. Using a donor car’s complete wiring harness simplifies the process, but it requires careful removal and routing.
Interior Modifications
Modifying your G35’s interior for a manual transmission swap involves several key changes to accommodate the new clutch and shifter. The most noticeable alteration will be installing the manual transmission’s clutch pedal assembly. This requires removing the automatic transmission’s accelerator pedal and installing the new clutch and brake pedals. Precise placement and alignment are crucial for proper operation and comfortable driving. The center console needs modification to fit the manual shifter. This often involves cutting or replacing sections of the existing console to create space for the shifter and its boot. You may need to source a manual transmission console from a donor car for a seamless fit. In addition to the pedals and shifter, you might need to modify or replace the floor mats to accommodate the new pedal positions. Some G35 models may require additional modifications to accommodate the manual transmission’s linkage and cables. Finally, ensure that the handbrake is compatible and properly installed. Careful planning and potentially custom fabrication may be necessary to achieve a clean and functional interior. Consider professional upholstery services for a factory-like finish. These interior changes are essential for a comfortable and safe driving experience after the swap.
Other Essential Components
Beyond the major components like the transmission and clutch system, several other parts are crucial for a successful G35 auto-to-manual swap. These often-overlooked items can significantly impact the final result. A new flywheel is essential, specifically designed for manual transmission use, providing the necessary interface between the engine and the clutch. The correct clutch kit, including the pressure plate, disc, and throw-out bearing, is vital for smooth engagement and disengagement. The driveshaft needs to be replaced with a manual transmission-compatible unit, ensuring proper length and spline count for seamless connection. The pilot bearing, situated in the crankshaft, guides the transmission input shaft, and using the incorrect one can cause damage. Don’t forget the necessary hardware, such as bolts, nuts, and washers, ensuring correct torque specifications are met during installation. Consider new gear oil specific to manual transmissions; using the wrong type can damage the transmission. A manual-specific shifter cable or linkage is also needed to ensure accurate gear selection. Lastly, a new clutch fluid reservoir and lines are necessary, ensuring proper hydraulic pressure to the clutch system. These seemingly small parts are vital for a smooth-running and reliable manual transmission.
Potential Challenges and Solutions
Converting your G35 from automatic to manual transmission presents several potential hurdles. Finding a suitable donor car with a manual transmission and all the necessary parts in good condition can be challenging, requiring extensive searching and potentially higher costs; The complexity of the wiring harness modification is another significant issue. Integrating the manual transmission’s wiring into the existing automatic system requires careful planning and execution, often necessitating specialized knowledge or professional assistance. Proper clutch adjustment is critical for smooth operation; improper adjustment can lead to difficult shifting or clutch slippage, demanding precise calibration and potentially requiring adjustments post-installation. The physical space constraints within the engine bay can also pose problems during the installation of the manual transmission, potentially requiring modifications or custom fabrication. Lastly, ensuring proper alignment and functionality of the driveshaft and axles after the swap is crucial to prevent vibrations and drivetrain issues, often needing precise measurements and adjustments. Thorough planning, meticulous attention to detail, and potentially professional assistance are key to overcoming these challenges and achieving a successful conversion.
Cost Breakdown and Budgeting
The cost of a G35 auto-to-manual swap varies significantly based on your approach. Purchasing a complete manual transmission swap kit from a reputable vendor provides a predictable cost, albeit a higher one. These kits typically bundle essential components, reducing the risk of missing parts and simplifying the process. Alternatively, sourcing parts individually from junkyards or online marketplaces can be more economical but increases the risk of acquiring damaged or incompatible components, potentially extending the project timeline and increasing overall expenses. Factor in the cost of professional installation if you lack the mechanical expertise for this complex project. Professional labor can significantly increase the final cost but ensures proper installation and reduces the risk of damage. Don’t forget additional expenses like new clutch kits, specialized tools, fluids, and potential unforeseen repairs. Creating a detailed budget that encompasses all anticipated costs is crucial. This includes not only parts and labor but also unforeseen issues, ensuring a realistic financial plan to successfully complete the conversion. Thorough research and price comparisons before purchasing any parts are essential to manage costs effectively.
Finding a Donor Car and Parts
Locating a suitable donor car is a crucial step in a G35 auto-to-manual transmission swap. A wrecked G35 with a manual transmission can provide many necessary parts, potentially saving significant costs compared to buying new components. Online marketplaces, salvage yards, and local auto parts stores are excellent resources. When assessing potential donors, inspect the condition of the manual transmission, clutch, and associated components carefully. Look for signs of damage or excessive wear. Document the donor car’s VIN to verify compatibility with your G35 model year and ensure proper part fitment. If a complete donor car isn’t feasible, sourcing individual parts is an option. Online forums dedicated to G35 enthusiasts are valuable resources for finding parts from other owners undertaking similar projects or upgrading their vehicles. Remember to verify the condition and authenticity of used parts before purchasing to avoid compatibility issues and potential mechanical failures. Documenting part numbers and comparing them to your G35’s specifications is essential for a successful swap. Consider purchasing new critical components, such as the clutch and pressure plate, to guarantee optimal performance and longevity after the conversion.
Step-by-Step Installation Guide
A detailed, sequential approach is critical for a successful G35 manual transmission swap. Begin by disconnecting the battery’s negative terminal for safety. Next, remove the center console and related interior components to access the transmission and related systems. The existing automatic transmission must be carefully removed, taking note of all connections and components. Install the new manual transmission, ensuring proper alignment and secure mounting. Install the new clutch assembly, meticulously following manufacturer instructions. The clutch pedal, master cylinder, and slave cylinder must be correctly installed and connected to the hydraulic lines. Connect the shift linkage, ensuring smooth and accurate gear selection. The wiring harness may require modifications to accommodate the manual transmission’s control system. Consult a wiring diagram for accurate connection points and avoid electrical issues. After installing the driveshaft, torque all bolts and fasteners to specifications. Refill the transmission with the appropriate type and amount of gear oil. Reconnect the battery and perform a thorough inspection of all connections. Remember, detailed instructions and diagrams are essential for this complex process. Consult service manuals or online resources for specific steps and torque values related to your G35’s model year. Professional assistance is recommended if you lack the necessary mechanical expertise.
Post-Installation Testing and Tuning
After completing the G35 manual transmission swap, thorough testing is crucial to ensure proper functionality and performance. Start with a visual inspection of all connections, ensuring no loose wires or improperly secured components. Then, carefully check the fluid levels in the transmission and clutch system, adding more if necessary. Before starting the engine, verify the clutch pedal’s free play and engagement point. Once started, listen carefully for any unusual noises or vibrations emanating from the transmission or drivetrain. Test the gear shifting mechanism, confirming smooth operation and accurate engagement across all gears. A road test is essential to evaluate the overall performance. Pay close attention to acceleration, deceleration, and gear changes under various driving conditions. If any issues arise during testing, address them promptly. A professional mechanic might be needed to diagnose and resolve complex problems. Fine-tuning might be necessary to achieve optimal performance. This may involve adjusting the clutch cable or hydraulic system for smooth engagement. After addressing any problems and performing necessary adjustments, another road test is recommended to verify the improvements. Detailed records of any issues encountered and solutions implemented are helpful for future troubleshooting. Remember, safety is paramount. Never operate the vehicle if you suspect any problems with the transmission or related components.