TeamCapri

Please login or register.

Login with username, password and session length
Advanced search  

News:

Remember! TeamCapri is a donation driven site. There are no ads here!

Author Topic: Auto to 5 speed swap  (Read 9766 times)

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Auto to 5 speed swap
« on: July 22, 2015, 11:55:44 PM »

I did the swap on my 1992.  I need to replace the clutch hose, fill up and bleed the fluids and give it a test ride.  Hopefully by Monday or Tuesday.
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #1 on: August 28, 2015, 12:43:04 AM »

I put new clutch master and slave cylinders and the clutch hose from a 1997 Mazda Protege.

I need to adjust the clutch pedal and take a drive.   8) 8) 8)
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #2 on: October 10, 2015, 11:52:40 PM »

Finally finished up, runs good.  I need to figure out how to get the "Manual Shift Light" to go off.
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

Rocketman

  • Administrator
  • Old-Timer
  • *****
  • Posts: 5492
    • 91 BPT AWD Capri & 1991 XR2
    • http://www.werbatfik.com
Re: Auto to 5 speed swap
« Reply #3 on: October 11, 2015, 12:23:29 AM »

Pull the bulb from the dash :p

Not really sure otherwise.
Did you swap ECU's? Rev limits okay?

Some cars have a neutral rev limiter for the auto trans, and require a method to defeat it when converting to a manual transmission (computer thinks it's in neutral all the time)

Can you give a rundown of the work required? It's been asked a few times, but I don't think it's ever been answered by someone who's been thru it themselves. Any snags or weird things you had to work around?
Logged
1.8L Turbo All Wheel Drive Capri... the "GTXR2"


Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #4 on: October 11, 2015, 04:41:07 PM »

It does rev high when it starts up cold but then settles.  I used the Auto ECU.  There doesn't seem to be any issue so far.

I will do a write up, but it was pretty straight forward.
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #5 on: October 11, 2015, 06:16:07 PM »

Here is my write up.  I may have missed something so ask if you have any additional questions.

Auto to Manual transmission swap on my 1992 NA Capri

Pulled from a local junkyard donor car:
   5-speed transmission, shifter and shift linkage
      I kept all the electrical connections on the "new" trans.
        Flywheel
   Clutch hose
   Driveshafts
   Clutch pedal
   Clutch saftey switch
   (You could get the clutch master and slave cylinders as well)
   
Purchased new:
   Clutch kit
   Clutch master and slave cylinder

Removed the battery, old trans, torque converter and driveshafts

Install the flywheel and new clutch

Install the transmission, driveshafts and clutch slave cylinder
   I replaced the seals around the driveshafts
   Fill with transmission fluid
   
Install clutch master cylinder
   On the firewall behind the battery
   Connect the clutch master and slave cylinders with the clutch hose.
   Fill with fluid

Install the clutch pedal, align and adjust the "plunger" with the master cylinder
   You should use one long rod to hang all the pedals
   Add a "strong" return spring between the clutch pedal and "under dash" (pic attached)
             https://drive.google.com/file/d/0B5r95s5jD6_0RUhXamFHVUxpRlVwWGVua25OMzVSQXJUcHF3/view?usp=sharing
   Adjust the "play" of the clutch pedal and the spacing between the clutch pedal and brake pedal to your liking

Bleed the clutch slave cylinder

Install a jumper wire on the connection that came off of the auto trans (or the car won't start)
   Between the black-red and the black-yellow wires (pic attached)
             https://drive.google.com/file/d/0B5r95s5jD6_0Q3ZHclppcE5MbFNfYWFBUlVkQmNOZER2RWdB/view?usp=sharing
             https://drive.google.com/file/d/0B5r95s5jD6_0NGgwdG1teTdMOFVuMmJZSEZDZzBZR2Jzb05v/view?usp=sharing
   I guess it is like the neutral safety switch on the automatics
   FYI: I haven't install the clutch safety switch yet

Reinstall the battery and test drive.
« Last Edit: October 12, 2015, 05:42:56 PM by Snigalfriz »
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

chrispoe

  • Sr. Member
  • ****
  • Posts: 435
    • 91 BP Capri GT
Re: Auto to 5 speed swap
« Reply #6 on: October 12, 2015, 10:57:10 AM »

I have a few question/comments.
Does your car have cruise control? If it doesn’t, you should be able to remove the 4EAT controller and the manual shift light should turn off.

When you listed the parts you used for the swap, you listed the clutch safety switch, but are you aware of the second clutch switch that has two sets of contacts?

Did you wire the two plugs coming out of the tranny up? Because looking at your pics of the plug with the jumper wire, you never wired up the red/white wire for the backup lights.
Logged

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #7 on: October 12, 2015, 01:28:04 PM »

I had cruise control as an automatic.  It currently isn't connected.

I was unaware of a second clutch safety switch.

I connected the wires from the "new" transmission, but nothing from the old transmission other than the jumper wire.

I did connect what appears to be the backup lights connection and also the other on the back of the transmission, but I don't have have backup lights when I put it in reverse.

Where should the red/white wire from the automatic transmission be connected?

Thanks Chris
« Last Edit: October 13, 2015, 10:31:47 AM by Snigalfriz »
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

chrispoe

  • Sr. Member
  • ****
  • Posts: 435
    • 91 BP Capri GT
Re: Auto to 5 speed swap
« Reply #8 on: October 13, 2015, 11:28:09 AM »

That red/white wire should be wired up to the reverse gear switch located on the front bottom of the tranny case (same side as the slave cylinder). The reverse switch has two wires, one goes to the red/white wire on the connector where your jumper wire is.

You should have another connector that has 4 wires: yellow, yellow/white, yellow/red, and a black/yellow. The black/yellow wire from this connector will get wired up to the second wire from the reverse switch.

I’m guessing the engine wire harness already had a plug on it for the tranny’s electrical connector on the backside (neutral gear switch). This is where the second clutch switch comes into play.
The clutch safety switch is activated when the pedal is pressed to enable the starter. The second clutch switch (the one with two contacts) is activated when the pedal is not pressed. One set of contacts is for enabling the cruise control. The second set sends a ground signal via the brown/black wire to the tranny’s neutral switch. The switch then passes the signal to the ecu via the red/blue wire so the ecu knows when the car is in neutral.

Logged

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #9 on: October 13, 2015, 11:38:57 AM »

I will check my connections.  I did plug the reverse gear switch into a another 4 prong plug that has a red/white and a black/yellow.  That is the connection that my other capri's, which is a factory 5-sp, reverse gear switch is connected to.
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

chrispoe

  • Sr. Member
  • ****
  • Posts: 435
    • 91 BP Capri GT
Re: Auto to 5 speed swap
« Reply #10 on: October 13, 2015, 11:48:26 AM »

If you connect the red/white wire to +12v do the backup light turn on?
When the ignition is turned on do you read +12v on the black/yellow wire?
Logged

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #11 on: October 14, 2015, 10:21:17 AM »

I will check that tonight.
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #12 on: October 14, 2015, 08:52:30 PM »

When I connect the the red wire to power the reverse lights come on.

When I connect the reverse gear switch to the red/white and black/yellow, but the black/red and black/yellow need to be jumpered and when they are the light doesn't come on.

What is the black/red wire?

When the car is running and I unjumper the black/red and black/yellow, the rpms go up.

Any ideas what I am missing?
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT

chrispoe

  • Sr. Member
  • ****
  • Posts: 435
    • 91 BP Capri GT
Re: Auto to 5 speed swap
« Reply #13 on: October 15, 2015, 10:08:56 AM »

Well at least we know the reverse lights work..LOL

If I’m reading your post correctly, you wired the other reverse switch wire to the same black/yellow wire that’s jumpered to the black/red? If this is how you have it wired, the backup lights could only be turned on while the starter is engaged.

In your pic https://drive.google.com/file/d/0B5r95s5jD6_0NGgwdG1teTdMOFVuMmJZSEZDZzBZR2Jzb05v/view?pli=1
The white plug with the jumper, the wires are:
Red/white= reverse lights
Black/yellow= ignition switch start signal
Black/red =starter solenoid

On top of the VAF in your pic is another connector, it should have 4 wires (if I’ve correctly identified the plug). This connector will have a yellow, yellow/white, yellow/red, and a black/yellow wire. This black/yellow is not the same as the previous white plugs wire. This wire provides +12V whenever the ignition is turned on and is the wire that you connect to the reverse switch.
Logged

Snigalfriz

  • Full Member
  • ***
  • Posts: 211
    • 1991 NA Capri
Re: Auto to 5 speed swap
« Reply #14 on: October 15, 2015, 01:30:00 PM »

Chris,

You are correct on what I was saying.  I wired in a kill switch between black/red & black/yellow.  That will get me by for now, but I will check the other connector.

Thanks for the information.
Logged
Why? I have more time than money, that's why I work on this car!

1991 Mercury Capri 5-sp
1992 Mercury Capri 5-sp swap
1999 Ford Contour SE 24v v6
2003 Lincoln LS
2007 Saturn Outlook XE AWD
2014 Chevy Cruze LT