Manual Conversion

[SupahStah]

Originally Posted by hppsc

Ok, if you don't know about something, why bother replying?

Ok, lets see, I gave as much knowledge as I knew, and I beleive it was fairly accurate. And stated where I wasnt sure.

Hypocritical paracite.

Supahstah

Originally Posted by SupahStah

Ok, lets see, I gave as much knowledge as I knew, and I beleive it was fairly accurate. And stated where I wasnt sure.

Hypocritical paracite.

Supahstah

hey man, I wouldnt worry about explaining yourself to yagz.....he's been banned but will no doubt pop up again with a different user name :P

[Christiaan]

Originally Posted by cringe

more pics and stuff at cold7.com :

Well, you've got more balls than me doing it on the floor in a garage!

Maybe you should degrease that box before you put it in? I'm guessing the EA motor had some oil issues? :P

[cringe]

yeah some oil issues.. as much on the outside as the inside..

yeah gonna degrease and clean up the gearbox before i put it back in.

garage floor is ok, bit hard on the back but when it's all you got it's ok.

gearbox was easy to get out, but pedalbox tested my patience, my patience is slim at the best of times, but when the plastic dash won't cooperate it has to break..

ok, going out to garage now to remove clutch and flywheel. :alien2:

[Christiaan]

Excellent, good luck

The EA flywheel and clutch is a 3 bolt setup.

I'd recommend going to a 6 bolt flywheel/clutch setup when you convert..

[RG]

Just be gentle on second gear in the EA boxes, I broke 4 of them even with a knackered clutch.

[Christiaan]

Originally Posted by GreenEL

Just be gentle on second gear in the EA boxes, I broke 4 of them even with a knackered clutch.

You broke 4 EA Boxes?? or 4 second gears? :P

[RG]

Originally Posted by shuresm58

You broke 4 EA Boxes?? or 4 second gears? :P

4 second gears but it was usually easier to replace the whole box. I replaced second gear once but the same thing happened. No problems with the EL box though....yet.

[cringe]

You can still see machining marks.


Clutch looks brand new!


They weren't lying when they said the clutch was recently replaced.
nice. just clutch cable to remove now, and then can wheel the beast out 'o the shed. :evil_laug

[cringe]

it doesn't appear that there are holes for the bolts of a six bolt clutch in this flywheel? reckon i'll just use this one anyway, as it's so good condition.

[Christiaan]

Originally Posted by GreenEL

4 second gears but it was usually easier to replace the whole box. I replaced second gear once but the same thing happened. No problems with the EL box though....yet.

Can i ask what you did to the box to make it throw 4 second gears? Be honest..

[RG]

Originally Posted by shuresm58

Can i ask what you did to the box to make it throw 4 second gears? Be honest..

With a knackered clutch for most of the time there wasn't too much that I could do to it and nothing that I haven't done to the current EL box. That said I could have been easier on it, a lot easier.

[boogernissan]

i have an ea wagon,started as an auto,converted to t5 with no dramas with ecm or anything like that....had trouble with pedal installation,pain in the **** to fit.shouldnt have any trouble with box they are tough and will take the punishment you give it..clutch doesnt though

[SupahStah]

Originally Posted by boogernissan

i have an ea wagon,started as an auto,converted to t5 with no dramas with ecm or anything like that....had trouble with pedal installation,pain in the **** to fit.shouldnt have any trouble with box they are tough and will take the punishment you give it..clutch doesnt though

The pedal is alot easier with a mel wood pedal pin kit :P dont even have to remove dash :P takes 5 - 15 mins hehe

[efgiar]

Originally Posted by cringe

it doesn't appear that there are holes for the bolts of a six bolt clutch in this flywheel? reckon i'll just use this one anyway, as it's so good condition.

i have an ea manual flywheel with 6 bolt holes ;) if u want 6 bolts then go out and buy an el clutch + pressure plate and take the flywheel to a toolmaker/machinist and they can drill and tap the extra 3 holes, thats wat i did cost me 50 bucks.

[falconkid]

can someone explain what a pedal pin kit is and what it does. im about to perform a conversion on my EL.

JIM

[XRated]

I can't believe you guys had so much trouble with the pedal box! I'm normally one to **** and moan, but I thought it was easy-going, just awkward at times... My biggest drama was the top bell-housing bolts.

I don't know how the pin-kit works, but you don't have to remove the dash or pedal box assembly.

[cringe]

the manual pedal box has a pin sticking out the side of it for the clutch pedal to hang off, so i assume the malwood kit consists of a pin that you either weld onto the box, or maybe bolt on? or clamp on? the pedal box has this pin plus a whole section with a switch on it that must tell the computer when you've put your foot on the clutch pedal.


here is the manual pedal box, note the pin that the pedal hangs from, and the switch.. why the computer needs to know when you put your foot on the pedal i don't know, but..

so yeah i assume the malwood kit consists of this pin, but in a bolt on style... anyone know for sure, or even better have a pic? and does it give you the clutch sensor/switch thingy??

[RG]

The switch disengages the cruise control. With the Mal Wood pin kit I don't believe that you get the switch.

[cringe]

cruise control.. why didn't i think of that :

so, today.. gonna pull out my instrument cluster, etc from the EL and see how hard it's gonna be to bolt in this pedal box.. gonna be a bit more careful than i was was the EA dash : hopefully it won't be too bad, the hardest bit in the ea was when i ran into the plastic tube for the driver side air vents (it was blocking all the top bolts of the pedal box.. will take a few pics and let you all know what trouble (hopefully none) i run into.

[Christiaan]

The good thing with the EA boxes, is some of them have been behind 3.9L CFI engines. They will be basically brand new, cos the 3.9L CFI isn't exactly the most powerful engine :P

[efgiar]

the only thing is the cruise correct but its easy to get used to after u redline ur car the first time :P oh well it was just a suggestion and it is alot easier, they bolt onto the hole and use the brake pin as support which makes it alot stronger, u could easily make up a braket for the factory EL cruise switch for the clutch and rivit it in, ull need to rewire the ea one as the plugs are different IIRC

[cringe]

man the EL pedalbox is looking like way too much of a headache to get out... how much do these malwoods kits cost? :

i see there's a hole in the box for the pin.. and yeah the brake pin is not far so i see how it could brace itself against that for strength.. and theres another hole not too far also... :Up_to_som

The good thing with the EA boxes, is some of them have been behind 3.9L CFI engines. They will be basically brand new, cos the 3.9L CFI isn't exactly the most powerful engine

Yeah, this EA had the 3.9.. so gearbox shouldn't have been too stressed out.

[Christiaan]

Originally Posted by cringe

man the EL pedalbox is looking like way too much of a headache to get out... how much do these malwoods kits cost? :

i see there's a hole in the box for the pin.. and yeah the brake pin is not far so i see how it could brace itself against that for strength.. and theres another hole not too far also... :Up_to_som


Yeah, this EA had the 3.9.. so gearbox shouldn't have been too stressed out.

Mate, you got further than me with changing the pedal box. I didn't even contemplate it, as i had done 2 or 3 before that, and I thought the $100 would save a lot of blood sweat and tears.

The pin bolts into the hole in the auto pedal box. Ring mal wood on (07) 4661 3548.

Ask him for a Clutch Pin for an EL Falcon for a manual conversion. It comes to around $100 with postage.

I have put one in my car, and it's holding up fine. I'm going to re-inforce it with a weld i think, just to make sure it doesn't break (if/when it will)

[Christiaan]

Oh, and also, you don't even have to remove/refit the manual brake pedal. All you have to do, is get a hacksaw/air saw, and cut down the automatic brake pedal down to the size of the manual pedal, and fit the manual brake rubber to the auto pedal.

All up, the under dash antics take approx 25mins or so, and it's complete. Then you can start fitting the gearbox!

[cringe]

the EL pedal box is a fair bit different..
there's bits on the el pedalbox that aren't even on the ea box..

so i don't think i'm going to be able to use the ea pedalbox anyway.
so now it's either get this malwood kit.. or try to make a pin kit myself..

from the bit in the ea box, i reckon i could almost copy it and create my own pin kit.
i'll have a play with the welder this arvo and see how i go.

so anybody wanna buy the pedalbox.. might whack it on ebay.
hmm..

[Christiaan]

Oh, and when fitting the pin, easiest way is to use a set of vice grips on the clutch pedal shaft bit, and a 19mm spanner on the bolt. I spent a while figuring out how to stop the shaft from spinning while i was doing it up hehe

[boogernissan]

my t5 started behind the 3.9cfi motor in a sedan and ended up in a 3.9mpfi wagon.both had standard clutch which took about a year of punishment.1st to 2nd snap shifts.clutch poopin.numerous sideways occasions etc draggin off holdens and stuff.blew two diffs up.fried the clutch after a year.gearbox is still good.engine hasnt missed a beat,recently put an el cam in it also has 2 and a half inch mandrell exhaust and custom cold intake.goes hard..3.9 rwevs to 5800 on occasions 5600 most days and hasnt disintegrated yet.have trouble diffs from leaf springs i guees.I LOVE MY WAGON

[efgiar]

u can try make ur own but u shoudl stick by rules of tolerance -+ .2mm... which is the usual standard for lathe/milling iirc from my engineering pre app days, i was considering making one myself be thought in the end the time i spend on making one, setting up machins and finding parts for it, i could probably have the pin kit at my door before i finish it.

u can knock out the pin out of the ea box and put it in the el on with a weld, that defiantly works as i kno someone who has done it before.

[cringe]

i have an old pedal pin from an xy.. it's the same diameter as the ea pin.
so gonna cut off the end and weld it to a plate, then either bolt or weld the plate to the el pedalbox. it even has the same groove for the circlip thingy.