Converting Auto to manual!!!

[Betta Carotene]

Due to the ongoing Th180 problems I will be converting the auto in the wagon to a 4 speed, and had a few questions. First would be what pedals do I need? Which speedo cable to use? I have the 4 speed here but would a 4 speed drive shaft work from a GT? I need a bunch of help with this guys! Thanks in advance.

[spdkilz02]

i would say get a pedal assembly from another kadett or kadett wagon if there is a difference, kadett speedo cable, and crossmember...that way u know that it will work and everything should be fine with it...

[opelbits]

Stick with Kadett parts. The parts book shows different numbers, so GT pieces will probably be different. Except for the trans, itself, it will bolt right in.
You need to determine which transmission you have. The key is the speedo drive. If it is a tube that sticks out from the trans and makes a turn, then you have an early trans, 68-70, and require the cable for those years.
Also, the shift tower needs to be the correct one. GT's lean, Manta's may be different from Kadett's.

I would assume that a GT driveshaft is too short, by a foot or so.

[Betta Carotene]

Well the reason I am asking if Gt parts fit is because I have soo many parts. Anyone out there have 4 speed kadett stuff? If so PM me please! Oh yeah and btw does a auto speed gear fit in a 4 speed?

[hrcollinsjr]

Has anyone done this conversion? The GT conversion is fairly simple if you have the parts. Is there an extra set of bolt holes for the shorter manual transmission?

Harold

[opelbits]

The major parts interchange, trans, bellhousing, flywheel, etc. It's the Kadett specific stuff you'll need. I don't know about the pedals, yet, but I have doubts. The reason for the 'non-interchange' is that the motor and trans sit further forward in the Kadett than the GT. The speedocable is a different length for that reason. The speedocables are the same auto and manual, but there are some length changes amongst the model years. Plus the shifter lever is taller. I don't know about the shifter tower, yet, either, but I do know a Manta unit is at a different angle.

I'd be willing to bet the correct mount holes are already in the Kadett chassis.

[Betta Carotene]

On the kadett the bolt holes for the manual trans are not there so some wiill have to be made. I can get a kadett clutch cable. The only worries now are the drive shaft and pedal assembly. Anyone got these things?

[neuropel]

Has anyone ever come across an Opel CIH crank with NO provision for the pilot bearing? Just curious...

[David McCollam]

Originally Posted by neuropel Has anyone ever come across an Opel CIH crank with NO provision for the pilot bearing? Just curious...

Todd,

Are you saying that the crank has no bore for the pilot bearing?

Dave

[neuropel]

Originally Posted by David McCollam Todd, Are you saying that the crank has no bore for the pilot bearing? Dave

No, I'm just wondering if that ever COULD BE the case. I've never seen one missing the bore for the pilot bearing but it seems I've heard of this before, either in Opels or some other make. This thread reminded me of it. If that were the case, suddenly it becomes a bigger deal to do the conversion. I'm guessing that with Opels, ALL cranks were setup the same way but I figure if someone has noted otherwise we'll hopefully hear about it.

[hrcollinsjr]

Originally Posted by neuropel if that ever COULD BE the case. I've never seen one missing the bore for the pilot bearing

Highly unlikely as this would create an increase in inventory for parts. The crank with the pilot bearing hole can be used in either engine and the cost of producing two different crankshafts for virtually the same application would make no sense. If a company will use suspension and other parts from different models to save money do you really think any of them would use a special crankshaft for the different types of transmissions?

Harold

[tonykim]

I've done this auto to 4spd conversion before on a 70 1.9L wagon. It's been over a decade but I can remember many of the details.

1. pedals - you need a longer pivot rod to hold both the brake and clutch pedal. this is a bolt in from manual trans Kadett parts.
2. clutch cable - I found a car in a boneyard and cut the clutch cable boot holder off the firewall of the donor, trimmed it up, painted it, and then drilled mounting holes in the firewall and bolted it right on.
3. rear trans mount - you're right, the Kadett doesn't have bolts for the crossmember of the shorter 4-spd trans. What I did was use the auto crossmember and rear mount. I made a ~.5 or .625 in thick steel plate that on one end bolts to the trans and on the other to the top of the trans mount. I experimented with this and spacers until I got the trans at the correct position so that the driveline angles were correct.
4. shift linkage interference with the floor pan - yep, believe it or not the shift linkage on the right side of the trans wouldn't slide past the floor for the 3-4 shift. So, I modified the tunnel about .5 - .75 in to clear.
5. shift console - the 4-speed consoles won't fit the different tunnel shape of the automatic. I ended up just making a ring that held the bottom of the shift boot down and screwed it to the floor.
6. I used the speedo cable from my 4-spd donor car
7. speedo calibration - yep, you guessed it this was wrong as well. I had a box of Kadett speedos so I just kept trying them until I found one that worked. I know, it's the opposite approach of going after the trans speedo gear. I used a 4-spd from a 74 Manta Rallye so that was probably the cause.
8. I planned on plugging the trans oil cooler in the rad but Opel used a weird fine pitch thread and I never could find something that would work.
9. Installed the pilot bearing in the end of the crank shaft.
10. I used a stock Kadett 4-spd driveshaft.

I have some pictures somewhere on my pc. send me an email at tonykim@bellsouth.net and I'll send you what I have.

Hope this helps.

[heimue]

I have lots of leftover Kadett parts. I might be able to provide a pedal assy'.
I'll be back home in a week, and will let you know then. Feel free to remind me if you don't hear from me after 2 weeks.

Dieter

[Opelkurt]

If it were me, I'd save up and put in a 5-speed Getrag.... The splined end of your automatic driveshaft would fit the Getrag; the driveshaft itself would just need to be lengthened a couple inches or so. If you drive a bunch the Getrag will pay for itself in fuel economy (after 100 years of driving, but it sounds good to the spouse... )

Regarding the clutch pedal, the GT parts (pedals and pivot shaft) should fit right into your Kadett.

-Kurt