Oblig's EK Auto to Manual Conversion [1/02: done!]
 

About a month ago I decided to convert my Civic from auto to manual.
The main reason for the swap is my long term goal of installing a turbo on this car since I don't like the idea of boosting an auto vehicle.

I have a friend that has done some pretty extensive car work, and I know another guy around my area that is doing the exact same conversion right now, and the plan is that once he is done, he'll help me out with mine.

I will document everything that goes on with the swap in this thread.

The car:
96' Civic EX Sedan
(72k mi)


tein s-techs, ebay projectors, red/white tails, fogs, jdm rear red H, type r lip, type r grille.
lip, grille, and side skirts painted to match body.
http://img140.imageshack.us/img140/7864/121207cj6.jpg

engine mods:
aem SRI, aluminum radiator, other minor stuff.
http://img132.imageshack.us/img132/8254/121207aon4.jpg


Now I am going to link to a few of the guides I used to research up on this swap (or ones similar to it).

Great guide; includes part #'s and pics:
http://www.honda-tech.com/zerothread...459&page=1

look up and buy individual brand new oem replacement parts at:
http://www.hondaautomotiveparts.com
(I found this site very useful to see how things go together too.)

Another guide; it is for EG's but it is the same idea for EK:
http://www.hondashowoff.com/forums/s...51&t=11282

I bought many of my parts from eBay user hondapartsunlimited
They have TONS of honda parts in stock and I got my pedal assembly,hydro lines, master cylinder, clutch resevoir, slave cylinder, tranny mount, and throttle cable all for about 150 bucks shipped from them.

I got lucky and acquired the tranny itself (an s40 B000 ex model with about 120k miles on it), the starter, stock 5 speed p2p ecu, shift linkage, stock shifter, side tranny mount, and an extra slave cylinder (just incase) all for $200 cash from a local guy.
His tranny also already had the VSS and fork on it. Be sure to check for those two things when you buy your transmission.

Here's a pic of what I got from the local guy:
http://img66.imageshack.us/img66/799...onpartswd4.jpg

And the ebay'ed items:
(items still in the mail so these are the pics from the listing. They are the actual items though.)

Passenger side tranny mount
http://img210.imageshack.us/img210/6...8473722kq3.jpg

throttle cable
http://img210.imageshack.us/img210/7...7389026cf9.jpg


pedal assembly
http://img210.imageshack.us/img210/2...0396584no9.jpg


hydraulic clutch lines/cylinders/resevoir
http://img210.imageshack.us/img210/2...9250925ru8.jpg


Also from eBay I bought a skunk2 dual bend short shifter with shift knob: ($140)
http://img210.imageshack.us/img210/6070/621og3.jpg

and some shifter bushings made by Energy Suspension:($15)
http://img210.imageshack.us/img210/6...161102gof8.jpg

Lastly I found a local listing for a "civic 92-00 ACT Pressure plate and XTD Chromoly 8lb Flywheel -- just $100 for both"!
they were both new in box so I gladly purchased them.

http://img262.imageshack.us/img262/5599/actxtdgs5.jpg

I plan to buy the clutch street disc, pilot bearing, release bearing, and alignment tool seperately but I want to make sure I get the right ones.

This leads to my first dilemma.

EDIT: nevermind that problem, it turns out the guy sold me a pp from a 92-02 prelude.
proper disc and pp has been ordered and recieved.

edit2: also turns out I don't need the throttle cable or passenger side tranny mount.

The plan is to get the swap completed before 2008, but I'm not rushing anything.


notice: to whom it may concern, I'm posting this on other forums too

RE: Oblig's EK Auto to Manual Conversion [dilemma with clutch setup]
 

That's a pretty aggressive goal. Get any of this figured out yet?

RE: Oblig's EK Auto to Manual Conversion [dilemma with clutch setup]
 

That alone shouldn't worry you, online resellers aren't going to photograph parts for every single application, most images are just a "representation"

It looks like the pressure plate will bolt to the flywheel though... do the holes actually line up?

RE: Oblig's EK Auto to Manual Conversion [dilemma with clutch setup]
 

hehe...and on the other forum he also already found out that the PP is for a lude and will not fit his car...just fyi (info he got from ACT):D


btw...sorry to hear about that meng...hopefully you can sell it and get some $$ back or something. Good luck on the swap

RE: Oblig's EK Auto to Manual Conversion [dilemma with clutch setup]
 

thanks for your concern :)

yeah I already have it up for sale.
and yep its for a 92-02 prelude, while the flywheel is actually the one I need.

This is slowly coming along, but I'm waiting for some more stuff to come in, and learning more every day.
The new years goal probably won't happen, but hopefully I'll have everything in my hands by early jan.

I'm definitely dropping in the manual pedal assembly early this week, so I'll let everyone know how that goes.

In other news, I was about to order a bunch of misc parts such as nuts/bolts/brackets from majestic honda that I spent hours sourcing by cross referencing guides etc, but I didn't want to order it last night until I had more time to make sure I got everything I neeeded and nothing I didn't need. Well long story short, that website clears your cart overnight so I'm going to have to do all that over again.

At least I pretty much know what I need now though.

RE: Oblig's EK Auto to Manual Conversion [dilemma with clutch setup]
 

new clutch disc/pp came in today. The flywheel fits, so yeah, the guy just gave the wrong pp to me. Oh well, I should be able to sell it and actually turn a profit.

I slapped the short shifter and new shift bushings onto the shift linkage today.
a local guy sold me manual throttle body for only $20 bucks! He also helped me with a few other things (cleaning up and rerouting some coolant lines that were taking up more space than they needed to).

On another note,
I found out I don't need to drop the whole steering column to install the new pedals. Infact I don't need to put in the whole pedal assembly! Just the brake arm and of course at the clutch pedal with it's bracket and all.

No need to mess with the gas at all which is cool.
I'm waiting for the misc parts to come in from hondaautomotiveparts.com so I can do the pedals soon.

RE: Oblig's EK Auto to Manual Conversion [dilemma with clutch setup]
 

Alright! as a Christmas present (to myself), I got some work done today.
I got the pedals and master cylinder/clutch reservoir done, pics below:

Attachment 30160

Attachment 30161

Here's the shift linkage with s2 dual bend installed and the new throttle body:

Attachment 30162

Merry Christmas everyone!

RE: Oblig's EK Auto to Manual Conversion [dilemma with clutch setup]
 

Last night I pulled the center console, driver seat, auto ECU, air intake, and did a couple other things to prepare.
Everything is pretty much ready to go :)

It is now 10:30am, and a few people are coming over to help do the bulk of the work.
stay tuned!

RE: Oblig's EK Auto to Manual Conversion [12/31:project underway!]
 

Everything went pretty well today, but the job isn't done.

I can say that everything automatic is no longer in the car.
Tomorrow it's just reverse of removal I suppose :)

Here are some pics.

bunch of stuff layed out in the garage--expect a mess if you're doing this swap!
Attachment 30074

Good riddance huge auto tranny!
Attachment 30075

somewhat empty bay
Attachment 30076

you can see the shifter and ECU--shifter is now completely out, didnt take a pic yet though
Attachment 30077


random pic
Attachment 30078

flywheel going on
Attachment 30079

RE: Oblig's EK Auto to Manual Conversion [12/31:project underway!]
 

about to say.... shouldnt thier be a bearing on the flywheel? doesnt look like you put it on thier...