Congrats to our New President Anguss!!
Remember to like us on Facebook!! - https://www.facebook.com/skylinesdownunder

Author Topic: Stagea Manual Conversion Guide  (Read 11904 times)

tRUkbOY

  • RB20DET
  • ***
  • Posts: 247
    • View Profile
Stagea Manual Conversion Guide
« on: July 03, 2006, 03:31:13 PM »
Having just successfully undertaken this project I thought I should share it with others, well I was asked to so here we go.

You will need :

4WD Gearbox (R33 GTS4 or GTR Box) – Be aware of push vs pull type clutch though as a pull type clutch setup is usually more expensive than a push type.
Flywheel (9 bolt turbo type) & Bolts
Clutch & Pressure Plate & Bolts
Bellhousing Bolts
Clutch Pedal (R34 Skyline or Stagea Pedal)
Brake Pedal (Stagea or cut the auto one down, R34 Pedal does not fit)
R33 Handbrake Lever & Bracket
Clutch Master Cylinder
Clutch Line
Centre Console (Stagea or cut & modify original with an R34 or similar)
Manual Spigot Bush
Access to a hoist & if possible a gearbox lifter
Plenty of tools (drill, etc etc)
Some friends to help you lift things
2 packs of Cigarettes
2 Dozen Beer (Quantity may vary depending on consumption levels)

Start off by getting the Stagea onto the hoist. Remove battery as its going to be in the way when you unhook the Trans cables which are located under it on the inner guard. Unplug all 4 plugs.


Remove lower dash plastics & steering columns shrouds. Remove centre console & shifter assembly. Unbolt footbrake assy & while your there the brake pedal aswell, you may need to lower the steering column to do this.

You will also find that the heater vent pipe is in the way, remove that too.
You should now be able to see the dummy holes for the clutch master cylinder.

Drill these out but very careful when pushing through as the steel is very thin & ABS brake lines are just on the other side.

Rebolt in your new or modifed brake pedal & vent pipe. Push your clutch master cylinder through & bolt up your clutch pedal. Don’t forget about the split pins!!!!

Might aswell remove your footrest while your there, pop the centre cover off with a screwdriver & undo the two 10mm bolts. Remove the ignition lock out cable from the auto shifter. Reassemble your dash.


Now you need to make a choice. Take gearbox out on its own or take complete engine/gearbox/subframe out. I recommend taking the entire unit out. I just pulled the gearbox & I think this is why it took so long to do. I’ll do the steps for taking the auto out on its own anyway.

Put the car up in the air. Remove the front driveshaft, rear driveshaft loop, rear driveshaft, starter motor, trans cooler lines, unplug the speedo pickup, undo the hydraulic line from the diff. Slide a gearbox lifter under the trans & lower it down a bit. Undo your bellhousing bolts so you can slide it back a little. Pop the rubber cover off the sandwich plate & undo the torque converter bolts. You should now be able to slide the box out, this is the part where you need some mates to help you out.
Now your box is out have a bit of  a look & you will see that there is no hole for the shifter (if you hadn’t noticed already that is).

You will have to cut a hole. Measure the distance on the gearbox for the shifter then mark it out on the trans tunnel from the sandwich plate on the engine. Work out how much of a hole you need. The hole is not centred but should be slightly towards the drivers side of the vehicle. Before you cut make sure all your cables are out of the way inside the cabin. Especially the ones for the airbag module.

While your checking cables back in the cabin; get a star screwdrive & remove you airbag module (CAREFULLY!!!!!!!), bolts will probably have loctite on them. Gently put it to one side.
Swap your R33 handbrake cable for to the position your old footbrake cable ran through. Refit your module (CAREFULLY!!!!!)

Now you need to remove the auto trans spigot bush from the back of the crank. Some people have different ways off doing it. I used a die-grinder then bent it in on itself until I could pull it out. Oil up & fit your manual spigot bush. Bolt up your flywheel, clutch & pressure plate. Looks like we’re getting somewhere now.


Might pay to bolt up your clutch line now while things are out the way & replace your thrust bearing. Hook up your handbrake lever to your cables aswell.
« Last Edit: November 16, 2007, 08:51:39 AM by tRUkbOY »

tRUkbOY

  • RB20DET
  • ***
  • Posts: 247
    • View Profile
Stagea Manual Conversion Guide
« Reply #1 on: July 03, 2006, 03:31:48 PM »
This is where it gets a bit tricky. You will need to tilt the motor back so you can meet up with the box. Do whatever you have to do to do it. Raise the box up into position while bringing it forward (surprise, surprise) & you will find the the trans tunnel is narrower than the box. You will be able to get the input shaft just about past the lower pressure plate fingers. If you are worried about damaging your car this is where you will realise that you should have dropped the whole subframe out.

Anyway, slide another gearbox lifter under the front of the box. Pump it up under the front of the box essentially forcing the trans tunnel (slightly) into the room you need, you won’t need much & the gearbox will slide into place & it will all of a sudden look like there is masses of room. Get the box bolted up & begin reassembling everything.

Hook up your clutch line to the box. Bolt up new bellhousing bolts, driveshafts, remove the crossmember from the auto & bolt it up to the manual box, plug in your speedo pickup, diff hydraulic line. Fill the box with fresh fluid and bleed up your clutch master cylinder.


You will now need to mount your handbrake lever, there is a bracket in the centre of the trans tunnel for the centre console, you will need to remove that. Weld, bolt, screw or pop rivet it onto your trans tunnel. Run the cable for the handbrake light from the footbrake position to the new handbrake. Fit/modify your centre console.

Go back to the front of car with the four plugs. The two pin grey plug is your inhibitor switch, put a loop between those (cut plug off auto trans loom). The brown plug is for the reverse lights (well two pins of it anyway), hook those up.

You should be about ready for some 4WD Heli’s!!!!!!!

Big thanks to Kelvin, Rob & Jason at The Cartune Company (tools & hoist), Brent, Jason at Te Rapa A/E, Ueli, Sjoerd & Phil, for the muscle power and help, & of course Corona for help with the inevitable dehydration & B&H for the stress relief.
« Last Edit: November 16, 2007, 08:50:16 AM by tRUkbOY »

szukalski

  • Guest
Stagea Manual Conversion Guide
« Reply #2 on: July 03, 2006, 05:36:05 PM »
Nice thread and great guide! Kudos on the manual conversion :D

adikt

  • RB26DETT
  • *****
  • Posts: 845
    • View Profile
    • http://
Stagea Manual Conversion Guide
« Reply #3 on: July 03, 2006, 06:52:54 PM »
nice effort, thought i recognised brent's ugly mug in that pic.
didnt notice you were in hamilton, ill have to come have a look at your stag & conversion.
(since no doubt gzzmos will rope me into helping with his :dfinger: )

Gzzmos

  • RB26DETT
  • *****
  • Posts: 1249
    • View Profile
    • http://
Stagea Manual Conversion Guide
« Reply #4 on: July 03, 2006, 07:49:18 PM »
Quote from: adikt
nice effort, thought i recognised brent's ugly mug in that pic.
didnt notice you were in hamilton, ill have to come have a look at your stag & conversion.
(since no doubt gzzmos will rope me into helping with his :dfinger: )


you read my mind :laugh: :p

SCR32

  • RB20DET
  • ***
  • Posts: 178
    • View Profile
Stagea Manual Conversion Guide
« Reply #5 on: July 03, 2006, 09:16:20 PM »
Quote from: tRUkbOY
...a pull type clutch setup is usually more expensive than a pull type.


So you been doing some pulling, aye..:dfinger:

bsm

  • RB20DE
  • **
  • Posts: 67
    • View Profile
Stagea Manual Conversion Guide
« Reply #6 on: July 06, 2006, 09:42:13 AM »
Nice work dude. Wish I was there to help you guys drink your beers :laugh: :laugh: . Congrats on your conversion and let us know how your Stagea goes
Haters Make Me Famous!

tRUkbOY

  • RB20DET
  • ***
  • Posts: 247
    • View Profile
Stagea Manual Conversion Guide
« Reply #7 on: July 06, 2006, 10:11:15 AM »
Quote from: SCR32
So you been doing some pulling, aye..:dfinger:


Good spotting. I've 'fixed' that now.

Stagea goes much better now, actually puts the power to the ground & is more predictable to drive. Definitely worth the effort

adikt/Gzzmos : you are both more than welcome to have a look anytime. Just gimme a yell sometime. I am quite often floating about down at Cartune on the weekends, Brent too actually

Gzzmos

  • RB26DETT
  • *****
  • Posts: 1249
    • View Profile
    • http://
Stagea Manual Conversion Guide
« Reply #8 on: July 06, 2006, 04:17:20 PM »
Quote from: tRUkbOY
Good spotting. I've 'fixed' that now.

Stagea goes much better now, actually puts the power to the ground & is more predictable to drive. Definitely worth the effort

adikt/Gzzmos : you are both more than welcome to have a look anytime. Just gimme a yell sometime. I am quite often floating about down at Cartune on the weekends, Brent too actually


thanks for the offer we'll been needing all the info we can get :D

adikt

  • RB26DETT
  • *****
  • Posts: 845
    • View Profile
    • http://
Stagea Manual Conversion Guide
« Reply #9 on: July 06, 2006, 08:05:54 PM »
sweet, might come in this weekend if i find some time & you guys are around.
either saturday afternoon in my skyline, or sunday in the work ute/van when i dont have to pay for gas :D

Gzzmos

  • RB26DETT
  • *****
  • Posts: 1249
    • View Profile
    • http://
Stagea Manual Conversion Guide
« Reply #10 on: July 06, 2006, 08:08:26 PM »
Quote from: adikt
sweet, might come in this weekend if i find some time & you guys are around.
either saturday afternoon in my skyline, or sunday in the work ute/van when i dont have to pay for gas :D


i wouldnt mind coming dude, give me a txt or a pm

FiShYmAn

  • RB20DET
  • ***
  • Posts: 207
    • View Profile
    • http://www.primowireless.co.nz
Stagea Manual Conversion Guide
« Reply #11 on: July 06, 2006, 09:09:37 PM »
can i come too? :P
Skylines Downunder Forums sponsored and hosted by:

http://www.primowireless.co.nz

adikt

  • RB26DETT
  • *****
  • Posts: 845
    • View Profile
    • http://
Stagea Manual Conversion Guide
« Reply #12 on: July 07, 2006, 06:42:35 AM »
haha, sweet as, ill give you a txt nic.
and fishyman - next time you ring me with your phone in your pocket im gonna answer & waste all your money :P

Gzzmos

  • RB26DETT
  • *****
  • Posts: 1249
    • View Profile
    • http://
Stagea Manual Conversion Guide
« Reply #13 on: July 07, 2006, 06:55:09 AM »
sweet as dude

FiShYmAn

  • RB20DET
  • ***
  • Posts: 207
    • View Profile
    • http://www.primowireless.co.nz
Stagea Manual Conversion Guide
« Reply #14 on: July 07, 2006, 08:04:46 AM »
fine! answer it, i have free minutes!!! :P :P does that mean i can come? :P
Skylines Downunder Forums sponsored and hosted by:

http://www.primowireless.co.nz