First, let's figure out what pushes drivers to take such a step. The main reason is a gearbox failure. The second is the desire to save money. We're talking about those who want to switch from an automatic to a manual to reduce fuel consumption, and sometimes to improve acceleration dynamics. There are more such enthusiasts than those who, on the contrary, seek to trade a manual for an automatic for greater comfort in city driving.
Swapping an automatic for a manual
The operation of removing an automatic gearbox and installing a manual one is noticeably simpler than the reverse process. Each car model is unique and requires its own approach, but there is a general procedure and a list of mandatory steps.
The technology of replacing an automatic transmission with a manual one in general terms looks like this:
1) Raise and secure the front of the car
2) Remove the lower engine panels
3) Remove the dashboard and instrument panel (the scope of work depends on the specific model)
4) Disconnect the battery terminals
5) Remove the starter (if it is located at the bottom of the engine)
6) Disconnect the gearbox wires from the protective cover
7) Unhook the automatic gear selector cable
8) Disconnect the speedometer cable or sensor
9) Disconnect the transmission fluid radiator pipe and drain the oil from the gearbox
10) Secure the engine on struts
11) Unscrew the bolts connecting the gearbox to the engine
12) Separate the intermediate shaft and the gearbox
13) Remove the support and brackets of the gearbox
14) Extract the torque converter
15) Using a jack, separate the automatic from the engine and remove it
16) Install the flywheel for the manual and the drive cables (not always required — depends on the car)
17) Replace the selectors
18) Install the clutch pedal and master cylinder
19) Install the manual gearbox
20) After assembling the interior, replace the electronic control unit (ECU)
These are the twenty main operations, but this does not mean that additional ones will not arise. Let us repeat: everything depends on the make, model, and even trim level. Moreover, behind the words "dismantling" and "installation" there are many auxiliary actions. For example, to secure the gearbox, clutch, and other components, you will have to find suitable brackets and mounts, and possibly rework the mounting points. You will likely also have to drill new holes. It is worth noting that in rare cases the ECU does not need to be changed — sometimes the unit is the same for versions with automatic and manual transmissions. But this is more of an exception. Most often, not only the unit but also the entire "harness" — the wiring bundle connecting the engine sensors and auxiliary equipment to the processor — needs to be replaced.
As Autoportal found out, some Ukrainian service centers provide this service. The price varies greatly depending on the make, model, and year of manufacture. For reference: the procedure for a VW Passat B5 will cost $1000-2000 — the exact amount depends on the engine and drive type. The gearbox itself (contract) is $500-600. Moreover, most components are used. The pattern is simple: the newer and more complex the car, the more expensive the conversion. Conversely, for older cars the price is lower. For example, for a Passat B3, replacing an automatic with a manual will cost $600-900. The gearbox (used) is from $200 to $350.
The list of necessary parts for an average car looks like this:
1) Manual gearbox
2) Selector
3) Selector drive cables
4) Flywheel (with fasteners)
5) Clutch disc and pressure plate
6) Engine and gearbox mounts
7) Brake and clutch pedals
8) Clutch master and slave cylinders
9) Driveshaft support bearing
10) ECU for the manual gearbox
Swapping a manual for an automatic
It would seem that changing the order of the addends changes nothing. But here this rule does not work. Removing the manual gearbox and everything associated with it is just the tip of the iceberg. Then the hardest part begins: a complete replacement of the wiring, and sometimes the instrument panel, plus the purchase of a huge number of parts, including:
1) Automatic gearbox
2) Automatic transmission radiator
3) Hydraulic lines to the radiator
4) Automatic selector with cables to the ignition lock
5) One or two wiring harnesses (essentially all the wiring)
6) Control unit (ECU) for the automatic
7) Relays and fuses
8) Instrument panel
9) Speedometer sensor
10) Reverse light switch
11) Pedal assembly (you can keep the old one if the extra pedal does not bother you)
12) Starter
13) Mounting cushions (not always)
14) Driveshaft (not always)
15) Torque converter (if not included with the gearbox)
Describing the step-by-step process of replacing a manual with an automatic is more difficult. But in general, the removal and installation operations are similar — except for the electronics setup and wiring routing. Let us focus on the key points:
1) Removing the manual gearbox
2) Removing the clutch
3) Removing the gearshift linkage
4) Removing the pedal assembly
5) Removing the flywheel
6) Removing the driveshaft/half-shafts (depends on the drive)
7) Disconnecting the clutch hydraulic lines
8) Installing the ring gear disc on the crankshaft
9) Installing the automatic transmission radiator
10) Installing the rear engine mount
11) Replacing the starter
12) Replacing the driveshaft (if necessary)
13) Replacing all wiring under the dashboard
14) Replacing the instrument panel (some craftsmen manage to adapt the old one)
15) Installing the ECU for the automatic
Trying to find out the approximate cost of the reverse conversion, we encountered a not very adequate reaction from the masters. Most often we heard something like "it's easier to buy another car" or "prepare half the cost of the car." One of the gearbox repair specialists explained that the main headache is the electronics and wires. If there are no diagrams and complete information about the car and parts, the venture will be not only expensive but also extremely difficult. According to him, the main difficulties are hidden in the little things, which are nevertheless critically important. For example, if the model was produced with the same engine but with different gearboxes, that is a big plus. And if not, you will have to select an ECU, fabricate mounts, and, in essence, "drill" half the car.
Moreover, the feasibility of such conversions is highly questionable. After all, an automatic for the same VW Passat B3 and B5 costs $350-500 and $1000-1200, respectively. And on the secondary market, cars with automatic gearboxes are on average 10-15 percent more expensive than similar versions with a manual.
But if there is time and hands — anything is possible. An example is car owners who have already performed such an operation. According to them, it is not as scary as it is described. However, it should be emphasized here that the make, model, and year of manufacture play an even more important role than when replacing an automatic with a manual. In the first case, there is a simplification; in the second, a complication. That is why replacing an automatic with a manual costs more and is in less demand.
