VK Calais Auto - 5spd Manual - Help?

[Mr Robbo - The General]

G,day Fellaz. I've had a VK Calais for ages now, anyway, I managed to blow a seal in the Standard Trimatic. Figured easy replacment. Then a 5sp Manual with all the parts including clutch, pressure plate, ring gear etc, fell into my lap.
Now im wondering about a conversion. Its prolly gunna end up being a bit of a job i know. I hear holden made it easy for emselves with the VK, same pedal setup etc. I just wanna find out a few odd bits that might hinder my way. Any info would be helpful. Im sure both tranz are the same dimensions? no need to change tailshaft? Cheers Fellaz.

[Mr Robbo - The General]

PS: Any electrical help would be MUCH appreciated. After the box is in, Got the reversing lights and dash lights to sort. Its got the digital VK calais dash. im hoping that wont be a problem.

[Goon]

If the idles off you might have to do timing and tuning again eg. the mixer / idle screw

Then again i havent done a gearbox conversion before.

Just trying to help

[Mr Robbo - The General]

Thanks goon. Ummm, Does any1 know ANYTHING about reversing lights for the manual? i got no clue how to set it up. lol, i spose i'll work it out. Im just curious as to the "reverse" light that comes up on the dash with the auto. Do i need to by-pass that once the manual is in? Also, any info as to the rear reversing lights that come on, how make them work, much needed/appreciated. thanks again.

[craigvk]

I know for sure that the rear reverse lights only come on in a VK Calais if the reverse lamp shows on the dash.
I am in the process of 'strongly' thinking about converting my VK 308 to my Aussie 4 speed but I haven't got any info to help.

I think vkberlina would end up posting in this thread, so Scott might give some info.

[craigvk]

Is your 5 speed manual a Celica box or an M76? I heard the M76 boxes are shit and not very strong.

[Mr Robbo - The General]

lol, thats a bugga, cause i think its an m76. Should be ok for the 202. As long as i dont work it too much. if it shits itself, i'll just get another upgrade lol. Its a work in progress and this is my first conversion so its all gunna be trail and error. Im not bothering with a new consol once the manual is in either, gunna get it re-covered without a consol. Should look pretty cool inside. Theres somthing on that matter i wouldnt mind knowing though.... VL dash mould into the VK? But i was hoping to keep the digital readout itself from the VK. Any1 know if thats pos? Cheers.

[Mr Robbo - The General]

I know for sure that the rear reverse lights only come on in a VK Calais if the reverse lamp shows on the dash.
I am in the process of 'strongly' thinking about converting my VK 308 to my Aussie 4 speed but I haven't got any info to help.

Forgot to say thanks for that. I dabled in the fine art of being an Electrician in a past life so that info has actually helped me. I know the general setup that the lights work from. lol, dosent mean its going to be easy... and i wanst an auto electrician either lol. Also, any inside info i get from doing this conversion i'll keep u posted about. Might aid u in some way.

[mal62]

Have a look at this site it has some help stuff in it as well as wiring diagrapms http://www.v6conversions.com.au

[Mr Robbo - The General]

Shit yeah! Thanks bro. I can use some of that electrical info for the reverse lights. I went out and had a bit of a sus this arvo, looks interesting lol. I dont think it will be TOO hard, its just gunna be a bit of mucking around. WHY IS IT that electrical is ALWAYS harder than MECHANICAL :@ lol. ah well

[mal62]

I've just finished converting my VR auto to a T5 Manual. doing the mechanical stuff is easy and quick it's all the electronic crap that takes the time & the grey matter to work out. I left the auto computer & harness in it and reprogrammed the memcal to a manual and changed it upto 155 kw with a high volume air intake and a 3 inch sports exhaust, it hauls some ass now heaps better then an auto, but as luck would have it i fitted a secondhand box not a reco and hmmmmmm lost 5th gear last night so its gotta come out again but thats no drama

[Mr Robbo - The General]

Awwww damn!. lolm those VR's do haula ss anyway! lol, my old vk calais does ok against the VR's.... Got nothing on the vs with the ecotecs. Yeah im deadset dreading the electrical troubles considering the computer shit in the VK... I do know a few auto electricians if worse comes to worse, im gunna have a crack at it anyway, i'll get it in and working, i've got no worry's there, after that it'll be a matter of making it work to its potential.

[mal62]

I have a vr 5 speed and a vs ecotech and i reckon the vr even as an auto blitzed the vs, the vs just seems sluggish yet everything has been check and its running a ok so beats the shit out me

[vkberlina]

lol, thats a bugga, cause i think its an m76. Should be ok for the 202. As long as i dont work it too much. if it shits itself, i'll just get another upgrade lol. Its a work in progress and this is my first conversion so its all gunna be trail and error. Im not bothering with a new consol once the manual is in either, gunna get it re-covered without a consol. Should look pretty cool inside. Theres somthing on that matter i wouldnt mind knowing though.... VL dash mould into the VK? But i was hoping to keep the digital readout itself from the VK. Any1 know if thats pos? Cheers.

M76 box on an EFI 202 not a good choice, I didnt get out of my street after putting one in my car, after thinking I had done a dodgy rebuild on the box I rebuilt it with larger circlips for 1st & 2nd gears it lasted a bit longer but after about 2 weeks 1st & second did laps through the box in pieces.

Ok you need to install a manual pedal box or change the brake pedal and ad a clutch pedal it is illegal to just add a clutch pedal, due to the sizing & positioning of the auto brake pedal.

You will need to install a spigot bush into the end of your crankshaft, you would be surprised how many people forget this, it just a little brass bush used align the input shaft of the gearbox and stop it moving around under load.

When you remove the Neutral start switch join the purple wires together as they are for the starter motor.

Next in the same group of wires you will see the ones for the reverse light switch these just connect ontot he reverse light switch on the manual gearbox, you may need to lengthen the wires.
If you need them I have wiring diagrams on my site.


From memory the gearbox crossmember & gearbox mount is the same, tailshaft I cant remember but from memory they are different, the borgwarner shafts I have seen are generally thinner in diameter. The unis are different between the shafts.
SHAMELESS PLUG: If you are after a Shaft I have a M76 borgwarner tail shaft to salisbury diff to suit a VK for sale, and a M76 borgwarner to 78 series borgwarner diff one as well. Both for a sedan.

You will also need to change the transmission tunnel cover to a manual one.

Also dont forget to block up the vacume line on the EFI manifold from memory its the second one back from the front.

i think this is the last its probably got a transmission cooler radiator in it just undo the lines a bit of auto fluid will leak out all up the system holds 6.1L of auto fluid including the converter. You wont need to block the holes left in the radiator its only in and out, I would flush it out with degreaser to try and stop any fluid exiting after the conversion.

If its a Calais I dont know how your cruise control will work after the conversion, but I suggest you get a second vacuum brake switch for the clutch pedal to if you push the clutch pedal in it disengages the cruise.

You wont have any worries with the digital speedo as the end of the speedo cable is the same between the Trimatic & M76, just check my site for the correct speedo gear.

cheers
Scott

[Mr Robbo - The General]

Thanks very much for all the info there vkberlina. Tell ya what, there are a few things that i had forgotten about there. That info is going to help alot, i think i'll be able to get another tailshaft to suit for next to nothing from the same sorce, but if not i'll def get in touch with you about the ones you have for sale. Im in Newy so its not too far away. I have a friend that is persisitant in telling me i wont need to change the tailshaft, i was a little suspicious of this as with most conversions a tailshaft change is usually needed. So your advice ont hat has pretty well backed up what i was thinking. Still, its would be nice to get away with usuing the same tailshaft, but i think your right about the M76 being different. Anyway thanks again! i'll keep you posted ont he progress and let you know how it all went. Im having trouble finding the time to get on with this, but i cant wait to hook in. Work will start on it within the next week or two. May the gods be willing i'll be finished before the end of may.... lol