1. Gather Parts and Tools:
- Manual Transmission: You'll need a compatible manual transmission, typically from a donor Bronco or F-150 with a manual drivetrain.
- Clutch Assembly: Clutch disc, pressure plate, release bearing, and flywheel.
- Manual Pedal Assembly: Including clutch, brake, and gas pedals.
- Manual Shifter Assembly: Including the shifter lever and linkage.
- Driveshaft: May require modification or replacement to match the new transmission's length.
- Transmission Mount: May need modification or replacement.
2. Disconnect and Remove Automatic Transmission:
- Disconnect battery, shift linkages, driveshaft, and other associated components.
- Remove the automatic transmission from the engine bay using proper tools and safety measures.
3. Install Manual Transmission:
- Position the manual transmission in place and secure it using the transmission mounts.
- Connect the driveshaft to the transmission.
- Install the clutch assembly and flywheel.
- Attach the manual pedal assembly.
- Connect the shifter assembly and linkage.
4. Wiring and Electronics:
- Some Broncos may require modifications or rewiring to enable compatibility with the manual transmission, such as updating the electrical connections and sensors.
5. Test and Adjust:
- Verify proper functioning of the clutch, shifting mechanism, and all related systems.
- Make adjustments as needed, including clutch pedal travel and shifter alignment.
6. Additional Considerations:
- Depending on the specific models involved, you might need to swap the transfer case as well to ensure compatibility with the new manual transmission.
- Custom modifications may be required, especially for Broncos equipped with electronic fuel injection systems.
- If using a manual transmission from another vehicle, you might need to source specific components like engine adapters or custom bellhousings.
Overall, this is a complex and demanding task that requires mechanical expertise, attention to detail, and potentially specialized equipment. It's recommended to consult with experienced mechanics or transmission experts, and carefully plan the project before attempting the swap.
