Here's a breakdown of what's involved:
1. Sourcing Parts: This is arguably the most challenging aspect. You'll need:
* Manual Transmission: Finding a suitable manual transmission for your specific 2.2L engine is crucial. The bellhousing must match your engine. Used parts are your most likely source, and condition is critical. You'll need to ensure it's compatible with your engine and year.
* Clutch Assembly: This includes the clutch disc, pressure plate, throw-out bearing, and related hardware. Again, compatibility is paramount.
* Clutch Pedal Assembly: This includes the pedal, master cylinder, slave cylinder, lines, and linkage. You'll likely need to modify or replace parts of the existing automatic pedal assembly.
* Driveshaft: The driveshaft from an automatic Shadow will not work. You need a driveshaft from a manual transmission Shadow. The length and yoke will be different.
* Transmission Mount: This will need to be replaced with one designed for a manual transmission.
* Wiring Harness: You might need to modify the existing wiring harness to accommodate the manual transmission's components, particularly the neutral safety switch, which is critical for starting the car.
* Shifter Linkage and Cables: You'll need the entire shifter mechanism from a manual transmission Shadow.
* Flywheel: The automatic flywheel won't work with a manual transmission; you'll need a flywheel designed for the manual transmission and clutch.
2. Mechanical Work: This is complex and requires precision:
* Engine Removal (Highly Recommended): While potentially possible without removing the engine, doing so makes the swap significantly easier and less prone to damage.
* Bellhousing Swap: The automatic transmission bellhousing needs to be removed and replaced with the one from the manual transmission.
* Transmission Installation: Installing the manual transmission requires careful alignment and proper torque specifications.
* Clutch Installation: This is a delicate process requiring specialized tools and knowledge to prevent damage to the clutch or transmission.
* Driveshaft Installation: The correct driveshaft must be installed.
* Clutch Pedal Installation: The clutch pedal assembly needs to be installed and adjusted properly.
* Shifter Installation: The shifter linkage and cables need to be connected and adjusted.
* Wiring Modifications: Any necessary wiring modifications must be done correctly to prevent electrical issues.
* Bleeding the Hydraulic System: The clutch hydraulic system needs to be bled properly to prevent air in the lines.
3. Final Adjustments and Testing: After completing the installation, there will be considerable adjustments and testing needed. This includes:
* Clutch Adjustment: The clutch needs to be properly adjusted for smooth engagement.
* Shifter Adjustment: The shifter needs to be adjusted for precise shifting.
* Driveshaft Alignment: The driveshaft must be properly aligned to prevent vibrations.
* Road Testing: A thorough road test is necessary to ensure everything is working properly.
In Conclusion: This conversion is a massive undertaking best left to experienced mechanics with access to a lift, specialized tools, and a parts car. The cost of parts and labor will likely exceed the value of the vehicle. Unless you have extensive mechanical experience and access to the necessary tools and parts, it's strongly recommended you reconsider this project. It's far simpler and more cost-effective to simply find a 1991 Dodge Shadow with a manual transmission.
