G35 Automatic to Manual Swap⁚ A Comprehensive Guide
This guide will walk you through the process of converting your Infiniti G35 from an automatic to a manual transmission. We will cover everything from selecting the right transmission to making the final adjustments.
Introduction
The Infiniti G35, known for its sleek styling and powerful V6 engine, offers a thrilling driving experience. While the automatic transmission provides convenience, many enthusiasts crave the direct connection and control offered by a manual gearbox. A manual swap transforms your G35 into a driver’s car, enhancing its performance and engaging your senses. This comprehensive guide will walk you through the intricacies of converting your G35 from automatic to manual, providing you with the knowledge and steps to achieve this rewarding transformation.
This swap is not for the faint of heart, as it involves a significant amount of work and requires a solid understanding of automotive mechanics; However, with careful planning, the right tools, and a dedicated approach, you can successfully convert your G35 to a manual transmission, unlocking its full potential and enjoying a truly engaging driving experience.
Choosing the Right Transmission
The heart of your manual swap lies in selecting the appropriate transmission. The most common choice for G35 manual swaps is the CD009 6-speed manual transmission, originally found in the Nissan 350Z. This transmission is known for its durability, smooth shifting, and compatibility with the G35’s V6 engine. When sourcing a CD009, ensure it’s in good condition, and consider purchasing a complete transmission kit that includes the necessary components like the shift linkage, shifter, and center console.
While the CD009 is the popular choice, other transmissions may be suitable, such as the JK40B or JK40C found in the 370Z. However, these transmissions may require additional modifications for proper fitment and functionality. Before committing to a particular transmission, research its compatibility with your G35 year and model, and consult with experienced mechanics or online forums for guidance on potential challenges and solutions.
Selecting the right transmission is a crucial step in your manual swap. Careful consideration of compatibility, condition, and availability will ensure a seamless transition and optimal performance for your G35.
Gathering the Necessary Parts
Once you’ve chosen your transmission, the next step is gathering all the essential parts for the manual swap. This will involve more than just the transmission itself. You’ll need a complete clutch kit, which includes the clutch disc, pressure plate, and throw-out bearing. A new flywheel is also necessary, as the automatic and manual transmissions use different flywheels. Ensure the flywheel is compatible with the chosen transmission and your G35’s engine.
Beyond the core drivetrain components, you’ll need various other parts for the conversion. This includes a new clutch pedal assembly, clutch master cylinder, clutch line, slave cylinder, and a manual shifter assembly. Additionally, the center console will need to be replaced with a manual transmission-compatible console. You may also need to acquire a new driveshaft, as the automatic and manual driveshafts are not interchangeable.
It’s crucial to gather all the necessary parts before starting the swap. This will ensure you have everything on hand and avoid delays during the installation process. It’s also a good idea to have a list of replacement parts, such as bolts, nuts, and seals, as you may encounter worn or damaged components during the removal and installation of the transmission.
The Swap Process
The manual swap process can be broken down into several distinct stages. First, you’ll need to remove the automatic transmission, which involves disconnecting various components, including the driveshaft, exhaust, and cooling lines. You’ll need to carefully detach the transmission from the engine and remove it from the vehicle. Once the automatic transmission is removed, you can begin installing the manual transmission. This process involves aligning the transmission with the engine, installing the clutch and flywheel, and connecting the driveshaft.
Next, you’ll need to connect the clutch pedal assembly and hydraulic system. This involves connecting the clutch master cylinder to the pedal assembly and routing the clutch line to the slave cylinder. The manual shifter assembly also needs to be installed, which involves connecting the shifter to the transmission and mounting the shifter boot. After the transmission is installed, you’ll need to adjust the clutch pedal and shifter linkage to ensure proper operation.
The final step is to wire the manual transmission. This involves connecting the transmission control module to the engine control module and wiring the reverse lights and neutral safety switch. This step requires familiarity with electrical systems and proper wiring techniques. Once the wiring is complete, you can test the transmission and ensure it operates correctly before taking the G35 for a test drive.
Removing the Automatic Transmission
The removal of the automatic transmission is a crucial step in the manual swap process. This involves a series of steps that require careful attention to detail and proper tools. Begin by disconnecting the battery to prevent electrical hazards. Next, remove the driveshaft, exhaust system, and cooling lines connected to the transmission. These components need to be disconnected to provide access to the transmission mounting points.
Once these components are removed, locate the transmission mounting bolts and carefully remove them. Depending on the year and model of your G35, there may be multiple bolts securing the transmission to the engine. Once the bolts are removed, gently separate the transmission from the engine. This might require some leverage and careful maneuvering to avoid damaging any surrounding components. After the transmission is detached, you can carefully remove it from the vehicle, being mindful of any potential damage to the floor pan or other components.
It’s important to note that removing the automatic transmission is a complex process that requires specialized tools and a good understanding of the vehicle’s mechanics. It’s recommended to consult a repair manual or seek professional assistance for this step, especially if you are unfamiliar with automotive repair procedures.
Installing the Manual Transmission
Installing the manual transmission is a delicate process that requires precision and care. Begin by positioning the transmission correctly, ensuring that it aligns with the engine and the mounting points. It’s important to use a transmission jack or hoist to support the weight of the transmission during this process. Carefully align the input shaft of the transmission with the output shaft of the engine. This ensures proper engagement and prevents damage to the transmission or engine. Use the correct bolts and torque specifications to secure the transmission to the engine.
Once the transmission is securely mounted, reconnect the driveshaft, exhaust system, and cooling lines. Carefully align the driveshaft and exhaust system to avoid any misalignment or interference. Ensure that the cooling lines are properly connected and secured. Reconnect the battery and double-check all connections for any potential leaks or loose connections.
Before starting the engine, it’s essential to bleed the clutch hydraulic system. This ensures proper clutch engagement and prevents premature wear. You can use a bleeder screw to remove air from the system. After completing these steps, start the engine and check for any leaks or unusual noises. If everything seems in order, take the vehicle for a test drive to ensure proper transmission operation.
Connecting the Clutch and Flywheel
Connecting the clutch and flywheel is a crucial step in the manual transmission swap. This process requires precision and attention to detail to ensure proper operation and prevent damage to the transmission or engine. Begin by carefully aligning the flywheel to the crankshaft, ensuring that the bolts are properly aligned and secured.
Once the flywheel is securely mounted, install the clutch disc, ensuring that the clutch disc is properly centered on the flywheel. This prevents uneven wear and potential clutch failure. Align the clutch pressure plate to the flywheel, making sure that the pressure plate is properly aligned and secured.
Use the correct bolts and torque specifications to secure the pressure plate to the flywheel. This ensures that the pressure plate is properly clamped to the flywheel, providing adequate pressure for clutch engagement. Finally, install the clutch release bearing. This bearing is responsible for releasing the pressure plate, allowing for clutch disengagement.
Wiring the Manual Transmission
Wiring the manual transmission is a critical aspect of the swap, requiring a thorough understanding of the electrical system and the connections required for proper operation. The process involves connecting the transmission’s wiring harness to the vehicle’s electrical system, ensuring that all the necessary signals are transmitted correctly.
This may involve modifying the existing wiring harness or utilizing a dedicated manual transmission wiring harness specifically designed for the G35. The wiring harness connects the transmission to various components, including the clutch pedal position sensor, reverse light switch, neutral safety switch, and the vehicle’s control unit.
Correctly connecting these components ensures that the transmission operates as intended and that the vehicle’s computer system recognizes the manual transmission. It’s essential to consult a wiring diagram specific to the G35 model and the manual transmission being installed to ensure proper wiring and functionality.
Post-Swap Adjustments
Once the manual transmission is installed and the car is running, there are a few crucial adjustments that need to be made to ensure optimal performance and drivability. One essential adjustment involves bleeding the clutch hydraulic system. This process removes any air bubbles trapped within the system, ensuring proper clutch engagement and disengagement.
Another important adjustment is setting the clutch pedal height. This adjustment determines the distance the pedal needs to be depressed before the clutch engages. Proper clutch pedal height ensures a smooth and comfortable driving experience.
You may also need to adjust the shifter linkage to ensure precise gear changes and proper shifting feel. This can involve making minor adjustments to the linkage rods or the shifter itself. Finally, make sure to double-check all the connections and bolts to ensure everything is secure and functioning correctly.
Benefits of a Manual Swap
Converting your G35 from automatic to manual offers a range of benefits, transforming your driving experience and enhancing the car’s overall performance. One of the most significant advantages is the increased driver engagement and control. A manual transmission allows you to directly control the gear changes, providing a more active and visceral driving experience.
Manual transmissions are typically more efficient than automatics, resulting in better fuel economy. This is especially noticeable during spirited driving, where manual shifting allows you to keep the engine in its optimal powerband. Furthermore, a manual swap can enhance the car’s performance by allowing for quicker gear changes and a more responsive throttle response.
The manual swap also adds a unique element of personalization and exclusivity to your G35, setting it apart from the standard automatic models. It’s a testament to your passion for driving and your desire to create a truly unique and rewarding driving experience.