Here's why it's so complex and what's involved:
* Transmission: You need a complete manual transmission assembly from a compatible 1996 Chevy truck that originally came with a manual transmission. The bellhousing, clutch, flywheel, and pressure plate will all be different.
* Driveshaft: The driveshaft length and possibly the yoke may need to be changed to accommodate the manual transmission's output.
* Clutch Pedal Assembly: You'll need to install a clutch pedal, master cylinder, slave cylinder, and all associated linkages and hardware. This includes modifying or replacing the floor pan to accommodate the pedal.
* Clutch Cable or Hydraulic System: Depending on the specific transmission, you'll need either a clutch cable or a hydraulic clutch system.
* Shift Linkage: You'll need the appropriate shift linkage to connect the shifter to the transmission.
* Computer Control: The 1996 Chevy truck's computer likely uses the automatic transmission's signals for various functions. You might need to modify or reprogram the computer to account for the absence of the automatic transmission or find a manual transmission-compatible ECU. This is a major hurdle.
* Wiring Harness: The wiring harness needs modification to eliminate any automatic transmission related circuits and potentially add wiring for the clutch switch.
* Flywheel and Torque Converter: The automatic transmission uses a torque converter. This will be replaced with a flywheel designed for a manual clutch assembly.
This is not a job for a novice mechanic. It requires specialized tools, significant mechanical knowledge, and access to a parts source. The cost of parts and labor could easily exceed the value of the truck, especially if you encounter unforeseen complications.
In short: Don't attempt this unless you have extensive automotive experience, specialized tools, and a good understanding of the vehicle's electrical and mechanical systems. It's far more practical and economical to simply purchase a 1996 Chevy truck that already has a manual transmission.
