g35 auto to manual swap
The G35 automatic to manual swap is a popular modification among enthusiasts, enhancing performance and control by replacing the automatic transmission with a manual setup, typically using a CD009 or similar transmission from a 350Z. This swap is often sought after for its potential to improve driving dynamics and reduce maintenance costs over time.
Overview of the G35 and Its Transmission
The Infiniti G35, produced from 2003 to 2008, is a sporty coupe or sedan known for its powerful VQ35DE V6 engine and rear-wheel-drive layout. Initially equipped with a 5-speed RE5R05A automatic transmission, the G35 was praised for its smooth acceleration and responsive handling. However, many enthusiasts have sought to enhance its driving experience by swapping the automatic transmission for a manual gearbox, such as the CD009 from the Nissan 350Z. This modification aims to improve driver engagement and performance, leveraging the G35’s sport-tuned chassis and engine capabilities. The swap has gained popularity due to the availability of compatible parts and the desire for a more hands-on driving experience.
Why Consider a Manual Swap?
Enthusiasts often consider a manual swap for the G35 to enhance driving engagement and performance. A manual transmission provides better control, especially in spirited driving, and can improve acceleration by eliminating torque converter slip. Additionally, manual transmissions are generally more durable and require less maintenance than automatics, reducing long-term costs. The G35’s sporty design and powerful engine make it an ideal candidate for a manual conversion, allowing drivers to fully exploit its capabilities. Many owners also appreciate the tactile feel and connection to the vehicle that a manual gearbox offers, making the swap a popular choice for those seeking a more immersive driving experience.
Benefits of Converting to Manual Transmission
Converting the G35 from automatic to manual transmission offers several advantages. A manual setup improves fuel efficiency by eliminating torque converter losses and providing better control over gear shifts. It also enhances driving engagement, offering a more immersive experience with precise control over acceleration and deceleration. Maintenance costs are typically lower for manual transmissions, as they have fewer complex components compared to automatics. Additionally, the manual swap allows drivers to fully utilize the engine’s power band, especially during spirited driving. The availability of compatible parts, such as the CD009 transmission from the 350Z, makes the swap feasible and cost-effective for enthusiasts seeking improved performance and reliability.
Planning and Preparation
Planning and preparation are crucial for a successful G35 auto to manual swap. This involves assessing feasibility, gathering necessary parts, and scheduling adequate time for the conversion.
Feasibility of the Swap
The feasibility of converting a G35 from automatic to manual is achievable with proper planning and resources. Nissan/Infiniti designed the G35’s transmission crossmember with bolt provisions for both automatic and manual transmissions, simplifying the swap. The primary components needed include a compatible manual transmission (such as the CD009 from a 350Z), a clutch, flywheel, and clutch pedal assembly. Additionally, wiring adjustments and ECU reprogramming are necessary to ensure compatibility. While the process requires mechanical expertise, it is a common modification among enthusiasts, with many online guides and forums offering support and detailed instructions to help streamline the conversion.
Required Parts and Tools
To perform a G35 automatic to manual swap, several key components are necessary. A compatible manual transmission, such as the CD009 from a 350Z, is essential, along with a clutch kit, flywheel, and pressure plate. A clutch pedal assembly and manual shifter must also be installed. Additionally, a hydraulic clutch line kit and bleed kit are required to ensure proper clutch operation. Tools needed include a transmission jack, socket set, wrenches, and potentially a clutch alignment tool. Specialized tools, like a blind hole puller for the transmission, may also be necessary depending on the specific setup. Proper preparation ensures the swap proceeds smoothly.
Understanding the Transmission Compatibility
When performing a G35 auto to manual swap, transmission compatibility is crucial. The Nissan CD009 transmission, commonly sourced from the 350Z, is a popular choice due to its bolt-pattern compatibility with the G35’s engine. This transmission is interchangeable with the G35’s VQ35DE engine, simplifying the installation process. Additionally, the transmission crossmember of the G35 is designed to accommodate both automatic and manual transmissions, eliminating the need for major structural modifications. Transmission compatibility ensures proper fitment and functionality, making the swap feasible for enthusiasts. Proper research and verification of transmission specifications are essential to avoid compatibility issues during the conversion.
Budgeting and Time Management
Budgeting for a G35 auto to manual swap requires careful planning, as costs can vary based on the condition and source of parts. A used CD009 transmission, clutch, and pedal assembly can range from $2,000 to $4,000, while new components may exceed $5,000. Additional expenses include tools, hydraulic lines, and potential labor fees. Time management is equally important, as the swap can take 6-8 hours for experienced mechanics and longer for novices. Breaking the project into manageable sessions, such as weekends, helps maintain progress without overwhelming the workload. Proper budgeting and scheduling ensure the swap is completed efficiently and within financial limits, making the process more enjoyable and stress-free.
The Swap Process
The G35 auto to manual swap involves removing the automatic transmission and installing a manual setup, typically using a CD009 transmission from a 350Z.
Removing the Automatic Transmission
Removing the automatic transmission from a G35 involves several key steps. First, drain the transmission fluid to minimize mess and prevent spills. Next, disconnect the driveshaft, transmission cooler lines, and electrical connectors attached to the automatic unit. Use a transmission jack to support the assembly while removing the mounting bolts. Carefully lower the transmission and slide it out of the vehicle. Special tools may be required to unbolt the torque converter from the engine. Ensure proper lifting equipment is used, as the transmission is heavy and cumbersome. This step sets the stage for installing the manual transmission, requiring precision and patience to avoid damage to surrounding components.
Installing the Manual Transmission
Installing the manual transmission in a G35 swap requires precise alignment and careful handling. Begin by attaching the clutch and flywheel to the engine, ensuring they are properly seated and aligned. Carefully maneuver the manual transmission into position, aligning the input shaft with the clutch. Secure the transmission to the engine using the appropriate bolts, tightening them in a star pattern to avoid warping. Reattach the driveshaft and any electrical connectors, ensuring all components are securely fastened. Use a transmission jack to stabilize the unit during installation. Proper alignment is crucial to prevent damage and ensure smooth operation. This step is foundational for the rest of the swap, requiring attention to detail and mechanical aptitude.
Clutch and Flywheel Installation
The clutch and flywheel installation is a critical step in the G35 auto-to-manual swap. Begin by removing the automatic transmission components and inspecting the area. Install the flywheel, ensuring it is properly seated and aligned with the crankshaft. Next, attach the clutch disc and pressure plate, making sure they are centered and securely fastened. Use a pilot bushing or alignment tool to guide the transmission input shaft through the clutch during installation. Tighten all bolts in a star pattern to avoid warping the flywheel. Proper alignment and secure fastening are essential for smooth engagement and to prevent future issues. This step requires precision and care to ensure optimal performance.
Wiring and Electronics
The wiring and electronics phase involves adapting the vehicle’s systems to recognize the manual transmission. This includes reconfiguring the ECU to disable automatic-specific sensors and signals.
Understanding the Wiring Harness
The wiring harness plays a critical role in the G35 auto to manual swap, as it must be adapted to accommodate the manual transmission’s electrical requirements. The automatic transmission relies on various sensors and solenoids that are not present in a manual setup. Enthusiasts often discover that the wiring harness needs modification to disable automatic-specific functions and integrate manual transmission components, such as a clutch pedal position sensor or reverse light switch; Carefully identifying and repurposing existing wires, or adding new ones, ensures proper communication between the engine control unit (ECU) and the manual transmission. This step requires a detailed understanding of the vehicle’s electrical system to avoid errors.
Reprogramming the ECU
Reprogramming the ECU is essential after a G35 auto to manual swap to ensure the engine computer recognizes the new manual transmission. The ECU must be updated to disable automatic transmission-specific functions and enable manual transmission operation. This process involves reflashing the ECU with custom software that removes torque converter-related codes and adjusts engine management parameters for clutch engagement. Proper reprogramming ensures smooth operation, prevents check engine lights, and optimizes performance. A professional tuner or specialized software is often required for this step, as incorrect modifications can lead to drivability issues or even engine damage. Accurate calibration is critical for a seamless transition from automatic to manual operation.
Hydraulic and Clutch System
The hydraulic and clutch system requires precise installation to ensure smooth manual transmission operation. This includes fitting a new clutch, flywheel, and master cylinder.
Hydraulic Line Installation
Hydraulic line installation is crucial for the clutch system to function properly. New hydraulic lines must be installed to connect the clutch master cylinder to the slave cylinder. Ensure the lines are routed correctly, avoiding any bends or abrasions that could cause damage. Use a manual transmission-specific master cylinder kit to maintain proper fluid pressure. After installation, bleed the hydraulic system thoroughly to remove air bubbles, which can cause spongy pedal feel or clutch failure. Double-check all connections for leaks and test the clutch operation to ensure smooth engagement. Proper installation ensures reliable and precise clutch control, essential for a seamless manual transmission experience.
Bleeding the Clutch System
Bleeding the clutch system is essential to remove air bubbles and ensure proper hydraulic fluid flow. Start by using a clutch bleeding kit, typically including a pressure bleeding tool or manual bleeding hoses. Attach the bleeding hoses to the slave cylinder bleed ports and submerge the free ends in a container of brake fluid. Pump the clutch pedal several times to force air and old fluid through the system. Check for bubbles and replace fluid as needed. Repeat until fluid flows cleanly without air. Proper bleeding ensures a firm pedal feel and precise clutch engagement, crucial for smooth manual transmission operation.
Interior Modifications
Interior modifications include installing a manual shifter and clutch pedal, replacing the automatic shifter assembly to accommodate the new manual components for optimal driving functionality.
Installing the Manual Shifter
The manual shifter installation is a critical step in the G35 auto-to-manual swap. It involves removing the automatic shifter assembly and replacing it with a manual shifter, typically sourced from a compatible Nissan 350Z or similar models. The process requires careful alignment to ensure proper gear engagement. The shifter is mounted in the center console, and the surrounding trim may need adjustments for a seamless fit. Once installed, the shifter is connected to the transmission via the shift linkage. This step restores the driver’s ability to manually select gears, enhancing control and driving engagement. Proper installation ensures smooth operation and precise gear shifts.
Adding the Clutch Pedal
Adding the clutch pedal is a crucial step in the G35 auto-to-manual swap, enabling proper control over the manual transmission. A compatible clutch pedal assembly, often sourced from a Nissan 350Z, is typically used due to shared platform components. Installation involves mounting the pedal on the left side of the driver’s footwell, which may require modifications such as drilling for secure fitting. After mounting, the pedal is connected to the clutch master cylinder, usually located on the driver’s side of the transmission tunnel. Hydraulic lines are then routed from the master cylinder to the slave cylinder near the transmission, ensuring compatibility and proper sealing to prevent leaks. Bleeding the clutch system follows to eliminate air in the hydraulic lines, crucial for smooth engagement. Adjusting the pedal for optimal free play ensures comfortable and precise control. Testing the clutch pedal post-installation is essential to confirm smooth operation and proper gear shifting.
Testing the Swap
Testing the swap involves starting the car to ensure smooth gear engagement, checking clutch operation, and performing on-road tests to confirm proper function and responsiveness.
Initial Start and Basic Function Tests
After completing the swap, the initial start involves checking for proper engagement of gears and clutch operation. Start the car, listen for unusual noises, and ensure the clutch pedal feels smooth. Test the shifter’s movement through all gears to confirm proper alignment and engagement. Check for any leaks from hydraulic lines or the transmission. Monitor the dashboard for error lights, as the ECU may need reprogramming. Test the clutch’s biting point by slowly releasing it while pressing the accelerator gently. Ensure the car moves forward or reverse without jerking or slipping. This step confirms the basic functionality of the manual setup before proceeding to on-road testing.
On-Road Testing and Adjustments
Once basic functions are confirmed, take the car for a test drive to assess real-world performance. Start in a quiet area to test low-speed maneuverability, ensuring smooth clutch engagement and gear shifts. Gradually increase speed, checking for proper acceleration and absence of slipping or hesitation. Test uphill starts to verify clutch bite consistency. Monitor shifter precision and ease of gear changes, especially under load. If the clutch feels too soft or hard, adjustments may be needed. Pay attention to any unusual noises or vibrations during acceleration or deceleration. Fine-tune the clutch cable or hydraulic system as necessary to achieve optimal performance and driver comfort.
Legal and Safety Considerations
Ensure compliance with local regulations regarding manual transmission conversions. Always follow safety protocols during the swap, such as proper jack stands and tools. Expertise is recommended.
Ensuring Compliance with Local Regulations
Before proceeding with a G35 auto to manual swap, it is crucial to verify local regulations regarding vehicle modifications. Many jurisdictions require inspections or certifications for transmission changes, ensuring compliance with emissions and safety standards. Failure to adhere to these regulations can result in legal consequences. Always consult local authorities or a certified mechanic to confirm the legality of the swap in your area. Proper documentation and adherence to guidelines are essential to avoid penalties and ensure your vehicle remains roadworthy. Compliance not only prevents legal issues but also guarantees the safety and reliability of your modified vehicle.
Safety Precautions During and After the Swap
Performing a G35 auto to manual swap requires strict adherence to safety protocols. Always work in a well-ventilated area with proper tools and jack stands, ensuring the vehicle is securely lifted. Disconnect the battery to prevent electrical hazards. Wear protective gear, including gloves and safety glasses, to minimize injury risks. Post-swap, test the vehicle in a controlled environment, such as an empty parking lot, to ensure proper function of the clutch and transmission. Avoid aggressive driving until fully accustomed to the new manual setup. Regular inspections of hydraulic lines, clutch components, and wiring are essential to maintain safety and performance.
A successful G35 auto to manual swap can significantly enhance the driving experience, offering improved performance and driver engagement. This modification is particularly rewarding for enthusiasts seeking more control over their vehicle. While the process is complex and requires careful planning, the end result is a more responsive and cost-effective drivetrain. Proper execution and thorough testing are crucial to ensure reliability and safety. For those willing to invest time and effort, the swap delivers a satisfying transformation, making the G35 a more enjoyable vehicle to own and drive. It’s a testament to the versatility of the G35 platform and the creativity of its community.