Automatic to manual transmission conversion

Checkbook, .. To run to the used car lot and buy what you want. Do not even consider this type of modification. Ninety nine percent chance the truck will end up in your front yard with a "For Sale As Is" sign in the window.

The floor is not shaped right to mount the shift lever. The brackets for the clutch pedal could be under the dash already, but you will have to figure out how to mount the rest of the system. A good place to start is by looking up various parts on an auto parts store's web site to see which ones are different between an automatic and a manual transmission truck. Start with the exhaust manifold and pipes. The clutch uses hydraulics, not a linkage, so the line has to be far enough from hot exhaust parts so the fluid does not boil. That often necessitates using parts that are shaped differently to maintain the needed clearance.

You are fortunate that this truck is old enough to not have computer controls for the transmission. If it did, the easiest way to do the modification would be to lift the body off the frame and set it onto a truck frame with the manual transmission already in it. It would not be practical or economically feasible to try to switch the instrument cluster, computers, and wiring harnesses, and all the stuff they are connected to. Be aware your engine computer runs the torque converter lock-up clutch in the transmission. With that missing, the computer will detect the missing electronics and set a diagnostic fault code. On 1996 and newer vehicles that will turn on the check engine light, then you will never know if a different problem develops since the light is already on. On a 1992 model, even if the check engine light does not get turned on, the fault code will stop some other self tests from running, so some potential problems will never be detected, and if they cause a running problem, with no fault code to direct you to the circuit or system that needs further diagnosis, you will have no idea where to start.

Before you pursue this any further, ask at some shops what they would charge to do this for you, and who would be responsible for finding the right parts. When you give up, ask a few independent mechanics if they would do this for you. Even if you were able to find someone to attempt this, you will be in a real lot of hours and frustration. This is nothing like changing radios or wheels.

My neighbor tried to have a diesel engine installed into his Dodge truck back in the late 1980's. He even supplied his own engine. By the time he gave up, the shop had demanded payment over three times what he was originally quoted for labor, and the truck still was not done. It never got finished because the cost was a lot more than what he could have bought a brand new truck for from the dealership, outfitted the way he wanted it. He had not considered the stronger springs, larger radiator, bigger tires, no way to mount the right power steering pump and alternator, etc, etc, etc. Save yourself all that agony and look at this as an opportunity to buy exactly what you want.

There are people who can do these types of modifications, but I can guarantee you I am not one of them. I have done engine swaps years ago, and I built a mid-engine Dodge Challenger for racing. It had to be street-legal, and it was real fun to drive, ... As long as I did not have to go around any corners. It had no heater, no AC, no speedometer, no carpet or interior for sound-deadening, and only a six-gallon gas tank, so I knew if it broke down, I would not be any further from home than I was willing to walk back! I worked every night and every weekend for six months to build that car, then I got to race it four times before my girlfriend at the time crashed me into a pile of smoldering ruble. The car is still sitting behind my house for the last thirty years. You are today where I was thirty years ago. Had I known then what I was in for, I never would have considered doing most of those projects. I wasted so much time and money to build scrap metal. We read about these projects all the time and how they go sour. I am trying to convince you to avoid that heartache.

I did replace the smaller automatic transmission in my 1978 Chrysler with their larger model, but I knew that everything was the same except for a slightly shorter driveshaft. The car had been available with that larger "727", and all the mounts, linkages, and hose connections were the same, something Chrysler was famous for. Basically I replaced an orange with a slightly larger orange, and I called it an orange. You are trying to replace a pumpkin with bench grinder so you can call it a chair.

Sorry, but I had to add some humor to this sad situation. Normally I would recommend you get a copy of the manufacturer's paper service manual, but in this case that will not tell you what is different. Sometimes they will show you a line drawing, and it will have an arrow pointing to an item listed as "with automatic" or "manual transmission only", but only when it is pertinent to the subject being covered. Even if you do figure out a part such as a bracket is different, you will not know why, or if you can work around that difference. Experience is the best teacher for that, but you are not going to find many people who can supply that knowledge.

If I have not convinced you yet, find a truck with a manual transmission in a pick-your-own-parts salvage yard, then compare it to your truck. Look at how the clutch pedal is mounted and whether you will need to replace the brake pedal to make room for it. If the mounting bracket is not in your truck already, you could end up replacing the entire dash board. You will probably want to own the donor truck so you can remove parts as needed. If you have to keep running to the salvage yard, you will spend more for parts than what the finished truck will be worth.

The only reason I can think of to attempt this is if the truck has sentimental value, but then you would want to keep it original. For practical purposes, there is no need to complicate your life unnecessarily. Buy what you want. Neither of us is better at building a vehicle than the manufacturer.

You are welcome. I will sleep better tonight knowing you saved yourself a lot of heartache and frustration. Come back and see us again.