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I'll add some eye candy tonight when I get home and post some pics of the car. My 97 wagon was finally converted to a manual. I don't know about too many LPT's that were swapped over, who knows, I may be first. I had the center console off earlier and had easy access to the wires (the wiring links below leave room for improvement.) but I forgot to take pics. Sorry.
I'm piecing together a complete manual swap kit, with all the parts listed below as well as some miscellaneous stuff that might make someone's life easier if they do it. Mine was pieced together painfully, mostly through the links below then some last minute oh, shit moments. I don't have an exact price yet, looking in the $1,500-$1,700 range, max. Do the math on the parts needed and I promise you'll hit $2,000 before you know it.
This is a compilation of some of the threads that are floating around on manual swaps:
How to source the parts
A breakdown of the wiring work
The actual trans swap
The add-ons and the misc. little things that can make your swap a nightmare.
Mechanical Parts:
VolvoSaabParts was where most people got their stuff (http://www.vandsautodismantlers.com/). I used EAP Auto Parts in Colorado. (303) 922-8397, there are plenty of junkyards around. My M56 was bought from LKQ (www.lkqcorp.com), it changed my mind about that company. It came with enough parts (cables, clips and bolts) that I ended up sending $250 worth of parts to the dealer and FCP Groton.
There are numerous little parts needed to complete the swap. If you're lucky, you'll get some of them when you order the trans. If you're not lucky, you'll have to work with a dealer or another source on getting these. I personally had a bad experience with the dealer (due to many other reasons), and decided to use FCP Groton for the parts. Call with part numbers and they'll have them shipped to you in no time.
Here is the link of the Parts Bible thread:
Parts Bible Thread
Some items were not included in that thread, they are mostly clips and other small things to make your life easier. You can probably re-use some of the stuff from the autotragic if you get creative, but for less than a $100, I didn't feel like messing with it.
From re-reading it: the cables are not included in that $100 figure. Cables alone are upwards of $250 at the dealer. There are cheaper options out there.
Shifter cables: 9176272
Shifter cable clip and washer: 942915 and 973968
Shifter bracket, retainer and bushing: 3520134, 3520135 and 3520136
Clips for shifter bracket: 3502507
Slave Cylinder replacement
Click me for part numbers and prices
ECU:
ECU info
Basically: your auto ECU works fine, there is some minor wiring to do, but there is no need to track down a manual ECU. I am running an auto ECU and I like that having my RPM's drop quicker during shifts.
Wiring:
Wiring info
PM me if you can't read the thread above, I have it as a MS Word document as well. It's missing parts on how to disable some of the wiring under the center console, but I'll update the thread as I get that info.
Pretty pictures of a swap:
Part One
Part Two
Misc:
Short thrwo shifters:
Short throw info
More of the same
Parking Brake Repair:
You'll already have the car off the road, so this is a good time to repair some damaged parking brakes components. Below are the part numbers from Trent, (854TGA+), pulled from his recent repairs, along with comments on sourcing the parts.
QUOTE
9209756-7 x 2 Park brake cables
274270-8 x 1 Shoe set
3546028-6 x 2 Return spring
1273836-5 x 2 Return spring
I shopped around for prices, Cables could be found cheaper but I didn't want to mess around with wrong cables. The shoe set was way way way cheaper at the dealer! Return springs dealer only item.
274270-8 x 1 Shoe set
3546028-6 x 2 Return spring
1273836-5 x 2 Return spring
I shopped around for prices, Cables could be found cheaper but I didn't want to mess around with wrong cables. The shoe set was way way way cheaper at the dealer! Return springs dealer only item.
Random shifting issues:
Hard shifting
I'll add to this as I can over the next few days.
