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240SX Auto to 5-speed Transmission Swap

A common problem you'll run into when finding your perfect 240SX is finding one with an automatic transmission. This kinda kills the sportscar aspect of owning this great car - but itís not that big of a deal. You can swap your auto for a 5-speed for $800-1000 providing you can do the labor yourself. I swapped mine in June Ď01...took 16 hours wrenching, but no air tools, and me alone. I did it again in June '02 (on a '98) in 12 hours with air tools and a little help...

And I then ran a FULL SECOND faster in the quarter mile:
Best with auto was a 16.6 @ 84, same mods with the 5-speed swap was 15.6 @ 89.

Here is all the info you need for this swap, and the links to a site which details the work.
Most this info was taken from posts on Freshalloy.com - Thanks to those who contributed:

All you need is all the parts associated with a manual transmission...

Master cylinder, clutch pedal, hard line from master cylinder, rubber line to slave cylinder, slave cylinder, transmission, 5-speed driveshaft, shifter, shifter boot + dash trim, transmission crossmember (rear mount), throw out bearing, clutch, clutch fork, clutch pressure plate, flywheel, MT flywheel bolts (6), MT pilot bushing, MT transmission bellhousing bolts...

And a FSM to do the work. It's not "black magic" - It's a remove and install job. Should be easy for mechanically inclined folks, and possibly a nightmare for mechanical-newbies or the mechanically-challenged...

The bellhousing bolts are similar, but different for the Auto and 5-speed transmissions...you may be able to reuse a couple, but you'll need new ones (length) for 95% of the bolts - Anyway, here are the part numbers and lengths:



Bolts = 08131-0601A / 60mm length / 4 needed
Washers = 08915-2401A / 4 needed

Bolt = 08131-0701A / 70mm length / 1 needed
Washer = 08915-2401A

Bolts = 08124-0301F / 35mm / 2 needed
Nuts = 08911-2401A / 2 needed

Bolt = 08124-0601F / 65mm / 1 needed
Nut = 09811-2401A / 1 needed

Bolt = 08071-0251A / 25mm / 1 needed

Starter Bolts = 01121-03751 / 95mm / 2 needed

Credit to "roycenagger" from Freshalloy for the part numbers listed here...

If you choose to get these from your local ACE Hardware (or wherever)...the bolts for the block are all M10 X 1.5 thread/pitch, so just find bolts of the correct length as listed above.


There was a site on the web a long time ago with very detailed info, but it's been a dead link for a long, long time...

I saved the electrical info page, and am hosting it here:
http://www.KA24DEvelopment.com/cwilfert/S14_tranny_swap_electrical.html


And I get asked all the time what it cost me - Hereís the breakdown:

I did my whole swap for ~$700:

Transmission = $250, talked them out of the core charge...
Flywheel = $60
Driveshaft = $75
Clutch = Free, used parts from friends = Centerforce pressure plate and a half worn stock disc...
Master and Slave cylinder + lines = Less than $100...
Clutch pedal assembly = $30
Brake pedal = Just cut it down to size...
ECU = Usually go for $100 or so...
Misc. bolts and fluids = Less than $50...

So thats just under $700...about the same as exhaust and a pulley, but those combined won't cut a second off your 1/4...
Just so you know it's possible - Just take your time gathering parts...

You can find quality, low mile, used stuff out there...
A good place to look is www.car-part.com...

Hints:

You can use your auto ECU until you find a 5-speed one...but you will have cold weather start issues every once and awhile -
Not that it won't start, but it may idle rough until warm...

Just cut the auto brake pedal off by and inch on the left side...just as good, and less $$$ and time...

The auto pilot bearing is a pain in the ass to remove, but there is a tool made to remove it. I didn't have one for my swap, but used it on the second one...took 5 minutes with it. I used a Dremel and a screwdriver first time around - Not a good method...

Any questions, e-mail me at orion@gru.net.






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