Written by Mike (Slow_AT_Talon) Mysterylectronic@aol.comPics by Ivan ( Chamuko ) Chamukogs_t@hotmail.com
Prior to starting I removed the battery, battery box, intake, and the boltconnecting the shifter cable and the clip that holds it in(I also do not have my washer fluid reservoir in my engine compartment)I also had a donor car and had all the nuts, bolts and other parts from that.Hopefully this will be adequte for all my fellow DSM'ers I started with the shifter assembly, first you are going to remove the centerconsole and the two bottom panels beneth the center console oneither side then disconnect the shifter cable by pulling out the pins, save thepins. You also need to disconnect the other (2) cables (they are the cables for the ignition lock andthe brake pedal release for theshifter)(pic), then disconnect the clip that holds the cable in place. You then need to remove the (4) 12mm bolts connecting the assembly to thechassis, Then unplug the harness conected to the shifter bracket, remove the bracket. You can now install thethe new shifter assembly youneed to use the bolts from the M/T as they are a different length. I then removed the (2) 12mm bolts holding the shifter cable tothe firewall directly behind the radio location(pic),pull the shifter cable out and put the new ones in tighten the two bolts backdown. You can now connect the cables to the shifter assembly, the left on goes to the one that controls the side to side movementsand the right on controls the fron to back. Use the pinsyou removed before to hold the shifter cables in place, you can now put all thepanels back. My next step was the clutch pedal (this is harder then the shifter assy.) Toprepare this step you may want to start in the engine compatment.If you have (4) relays you may have to move them over and only use one bolt onthe bracket(pic). Then peel of the (2) silver stickerscovering the bolt holes that mount the clutch fluid reservoir. Now it's backinside the car, if you look up under the dash all the way to leftyou will notice two cut-outs in the material (one on the firewall and one on thetop)(pic) pull both off boh of the cut-outs. you will noticeon the firewall side there are (3) circular cut-outs going through only one partof the firewall these are the sizes the holes need to be (pic).I used a drill and different sized drill bits and I have heard of people using adremel but my drill bits were very fast. I used the flathole-saw bits. It's not important if the holes are bigger than the cut-outs asthe clutch master cylinder mounts to the pedal bracket.You should now check to see if the clutch master cylider fits and trim ifnecessary. Now mount the clutch pedal by using the (2) boltsthat you should get from the M/T car. Put the (2) 12mm bolts in first then slidethe clutch pedal bracket in and push it as far up to thefirewall as possible then tighten the bolts down. Go back to the enginecompartment and place the master cylinder in the new holesand then put the nut on the bolt facing you and mount your fluid reservoir(pic). Go back inside the car and place the other nut on the bolt facing you. You do not have change the brake pedal but you do have to cutthe left side to allow the clutch pedal to travel forward and to make sure that you dont slam on the brake instead of pressing theclutch. I cut mine with a grinder. Now it really starting to look like a stick shift but here is the hardest part.Start by dropping out the front mount and framethat it is attached to and drop your exhaust from the header. Take out youraxels and take out the (2) 18mm bottom boltsholding on the plate(pic) covering the bolts connecting your torque convertertake off (4) bolts with an 18mm wrench(pic), you will need to spin the crankshaft using a 19mm to access all these bolts. Oncethose are off you can undo the rest of the 18mmthere should be (2) more under the car and you may have brackets my car didnot(pic). Undo the other 18mm there are (2) on top (pic)and (1) more on the front (pic) and the starter bolts ?mm. The tranny shouldseperate a litte if not pry on it some if not still check to see if there are more bolts I didn't mention or that you missed. Now support thetranny with a jack and undo the back mount, I suggest taking off the (1) 14mm bolt as you do not have to use this mount braket againyou will need a 14mm wrench and socket for this part(pic).Once thats done you can remove the other tranny mount you will need a 17mmwrench and socket. I recommend taking out the (3) boltsconnecting to the mount to the tranny first then the nut and bolt coneecting itto the car as you will reuse this mount(pic).Connect your modular clutch with the bolts that were connected to the torqueconverter, slide on your Clutch release bearing to the tranny and don't forget to grease it or you have ahorrible noise. Now you can put in the transmission,My friend and I picked it up and slid it on but you should probably use a jack,the hardest parts are being able to get it to slide on,getting the differential onto the right part of the cross-member,and gettingline up with the first bolt hole then bolt it up using the sameprocess you took it off with. Reinstall your mounts and new tranny mountbracket. Now you should connect the clutch line and slave cylinder there are (2) 12mm bolts that connect it to the tranny bleed theclutch slave cylinder with the 10mm bleeder valve and after its bled check for proper operation, if all is well proceed. Connectthe shifter cables to the tranny you will need washers,clips, and pins to conect them, I did the clips first, you need to pull thecable back and feed it through the holes for them(pic) then pull itforward and push the clip on and possibly bang it down with something. Now slidethe ends over there poles and place a washerover them after that place pins in the holes of the poles. Replace axels, frontmount and other stuff that you removed. I then proceeded to do all the electrical stuff and I had the M/T computer so Ireplaced mine with that. The speed sensor is kindaghetto but it works. I piggy-backed each wire to the corresponding wire on thePCM plug (Yellow with white stripe to same color,yellow to yellow and black with green to same on PCM plug) You can remove theTCM you dont need it anymore. I did notdo the reverse sensor yet as it does not bother me. I then started it up andtook it for a spin. What weird feeling, my car but not!I would highly recommend it! Anyone want to make changes to be more accurate feel free to modify it in anywayto help more prople