Another Auto to 5 Speed Thread (Parts List)

[McGyver]

I am trying to put together a parts list for my 1991 auto to 5-speed swap. I’ve pulled a few trannies to replace clutches and reseal them, but never a conversion like this. I’m hoping someone can verify that I have thought of everything. Parts with a “*” next to them are ones that I can see buying from the junkyard to keep costs down, but input on what can be bought used would be helpful too.
Conversion
-Master/Slave Cylinder*
-Reservoir to Master Hose*
-Master to Slave Hose*
-Manual Flywheel*
-Manual Driveshaft*
-Flywheel Bolts x 8
-Transmission*/Support*/Mounts*
-Pedal Box*

Shifter
-Carrier Arm*
-Selector Rod*
-Bitch Clip*
-Z3 Lever
-White Plastic Cup/O-rings/Spacers/Rubber Seal/Boot*/Knob*

Seals
-Shift Shaft
-Output Shaft (engine/tranny)
-Input Shaft (tranny)

Clutch
-Clutch
-Pressure Plate*
-Throw-Out Bearing
-Pilot Bearing
-Throw-Out Arm
-Pivot Pin
-Retaining Spring*
-Clutch Bolt x 6
-Pressure Plate Bolt* x 6

[mikewbd]

Why reuse pressure plate bolts, new fasteners can't be that expensive.

[nando]

Why reuse pressure plate bolts, new fasteners can't be that expensive.

because McGyver...

also, i wouldn't reuse things like springs, clutch forks, pivot pins, etc. these parts are cheap and make sense to replace. You don't want to pull it apart later over a $5 part that you re-used.

I'd also strongly suggest replacing the selector rod joint. I wouldn't use old mounts either, but at least those are easy to replace later if they fail.

[Wanganstyle]

I'd strongly suggest buying a NEW stainless hose from master to slave; as the original e30 items are rubber and do degrade over time if you are planning on junkyarding one. One can buy a longer stainless hose to avoid using a flex + hard line if desired.

the fluid feed line is also rubber and could use a brand new OEM part.

[McGyver]

well the pressure plate bolts will only be $3, so I might as well get new ones. I just remember reusing them when I was working at the shop over the summer. The spring is also about $3 so getting a new one would probably make sense too. I was just being penny smart and pound foolish about them.

When it comes to pulling a junkyard tranny, is there anything can look for to pick one transmission over another? All I can think of is to look for a low milage one based on the cluster (which doesnt really mean anything) and to drain the fluid to see how clean it looks. I guess looking for one that doesnt appear to have past seal leaks would also be a good idea.

[Wanganstyle]

well the pressure plate bolts will only be $3, so I might as well get new ones. I just remember reusing them when I was working at the shop over the summer. The spring is also about $3 so getting a new one would probably make sense too. I was just being penny smart and pound foolish about them.

When it comes to pulling a junkyard tranny, is there anything can look for to pick one transmission over another? All I can think of is to look for a low milage one based on the cluster (which doesnt really mean anything) and to drain the fluid to see how clean it looks. I guess looking for one that doesnt appear to have past seal leaks would also be a good idea.

changing seals is highly suggested on any G260; they are um.....at LEAST 20+ years old :)

[jeffnhiscars]

I would suggest not using used mounts, hydraulics or pressure plate