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Re: 5-speed conversion parts?
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Posted by Saana88 [Email] (#207) [Profile/Gallery] (more from Saana88) on Wed, 25 Oct 2006 19:04:18 Share Post by Email
In Reply to: 5-speed conversion parts?, Jan Markham, Tue, 24 Oct 2006 17:49:02
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You'll need some comsumable parts:
New taper pin for the shifter connection (don't count on the old one being salvageable, and don't take it apart unless you have to)
Engine to transmission gasket
O-ring for oil pickup tube, if the replacement part is in bad shape
New ball joint bolts or ball joints
A-arm spacer tools
Clutch spacer tool
Flywheel locking tool
Thread locking compound
Anaerobic sealant compound
Enough CV joint grease to regrease both inner drivers
Stiff wire to hang the driveshafts in the car after separation
Plastic wrap and plastic bags to cover the inner drivers after separation
New coolant
Engine oil and filter
Power steering fluid
Enclosed garage (my swap was in the first week and a half of January 2003 in Roch)
Engine hoist
Wood blocks to set the engine/trans assembly on when separating/mating
Torque wrenches
Penetrating oil
Transmission fluid and gaskets (optional)
Small round punch (for aligning the shift linkage)
Triangular-nut tool (for removing and affixing the shift linkage) and needle-nose pliers
A full complement of straight and ball-ended hex (allen) wrenches
3.5 tons of patience
Paper labels (use on the engine wiring harness and label EVERY connector as you take it apart!)
Digital camera (use to document what you're doing in the beginning for when you forget what goes where at the end)
A helpful assistant (so greasy fingers don't mess up the digital camera or just about anything else when your hands are full of CV grease)
Exhaust header to downtube gasket (may be different in your case since you're dealing with turbos)
Battery charger (optional)
Fuel rail sealing washers
Fire extinguisher (listed as something you hope you never need)
Feeler gauges (I'm unfamiliar with the older-style front brakes)
Anti-sieze compound
Large pieces of cardboard (floor covering)
Two very sturdy jack stands, two wheel chocks
French onion dip containers (a running joke, use these to collect fasteners that go in similar locations, or to catch draining fluids, or a million other uses)
Two large subs (use for dinner)
Nitrile/latex/plastic gloves (here I am referencing how messy CV grease is again)
Rubber bands and binder clips (use for marking and holding pages in the Bentley)

While I was doing my swap, I siezed the opportunity to remove the AC system from the car. It was dead and I didn't plan on fixing it. If you intend to do this, you'll also need a cabin air filter insert or another cover for the hole where the evaporator currently is.

I don't think the engine mounts are going to change unless you're using a (shorter-geared) non-turbo transmission on a turbo car.

Words of advice: Take some time now to put in the spacers and remove the ball joint bolts, or at least to see if they still move. You've already been told about what to do while the motor is out, but here's the list of things I remembered (crank pulley and seal, rear motor mounts) and things I should have done (upper A-arm bushings, oil pump and timing cover gaskets, remove AC evaporator and condenser).

Hints: either photograph the ignition switch or use my blurry pics (from an '87, how convenient!)
Best of luck to you. You may be amazed when it all goes back together!
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