Gsi carlton auto to manual conversion.

[levin1620]

Hi chaps, I've recently bought a Gsi carlton(auto) and my plan is to covert it to manual, Is there anybody that has done this before and mite possibly take the job on? Or even recomend someone that could do the job that's not going to charge a bomb, don't mind helping or traveling within reason( based in London)
Thanks in advance

[nomad]

I've not done this on a Vauxhall but swapped a dead automatic engine & box for a working manual on a on a Nissan 200 (RWD, 2 litre), it was fairly simple. 

before starting, check :
propshaft. if manaul box is different length to the autobox, you'll need a matching propshaft.
flywheel/clutch/spigot bearing - check Vauxhall forums or wait for a reply on here to see what's needed (best case just remove the auto bits and bolt on a manual flywheel & clutch)

checkist :
remove autobox. Doh!
cut down brake pedal to "normal" size
fit new (used) clutch pedal & master cylinder - after drilling bulkhead to suit. Or before - your choice   
flywheel / clutch (not a problem for me as it was already on the good engine I was fitting)
the auto inhibitor (2 big wires to gearbox) needed to be spliced together or engine thought it was in auto-drive and wouldn't start.


Don't forget to let DVLA & your insurance company know about the change (sounds simple but might not be...)

[john911sc]

As far as i remember the ecu is different in the pair of cars so be carefull of that

[rwdrules]

ecu the same no problem just ground out one pin(cant remember the number)
auto prop is shorter than manual or other way round lol either way front end of one swaps nicely with the other to give the correct length,
clutch master cylinder is a curse word to do as its right up against the bulkhead,and has to go in after the pedal box,
isolater for the starter has to be rejigged to alpw it to work properly
some say the down pipe is different from manual but all the ones i changed cos i hate sludgepumps i never had a problem,
don't forget the spigot bearing,
however the r28 box does not have particularly good ratio,s in my opinion,r25 is cable clutch don't go there 24v torque wil shag it quickly ,
if i was doing it i would try to source a monza manual box(easier said than done mind)
as its well strong good ratio,s bolts straiht up but does require a smf which can be made up easily enough,this is also a cable clutch but a much better box,
Bastrdchild can probably add anything i have forgotten,
it is a worthwhile conversion though!!

[levin1620]

Thanks for the replys, I was aware that the ecu was slightly different but I can bye pass that problem. I've managed to gather up the following, from a 12v Gsi.
Gearbox
Propshaft(front section)
Gearstick
Gearstick mounts
Pedal box
Clutch
Flywheel
Spigot bearing
Only thing I am missing is the clutch master cylinder.
My cartlon is a 24v, now I was under the impression that these parts are the same only thing being that the 12v is a cable clutch?? Correct me if am wrong! I have been talking to a member on here and he possiabley could have everything I need from a 24v (yet to get back to me) and if that's the case I'll go that route. Now just looking for someone that would like to take the job on but it's looking like I'll end up chancing it myself which I don't mind, but living in London I don't have much garage space which could be a problem.

[chris y]

Is the 12V gearbox not R25? Its cast on the side. If so I would consider the other one you have an option of.

I've never converted one but have a couple of manuals with the standard R28 gearbox which I'm happy with.
I had no gearbox troubles in many years until the car I've got in bits now, the output shaft is flopping about so the box is being replaced, its done less than 200k hard miles, I have seen them do more without problems.

Sorry I couldn't be more help.