Auto to manual conversion

obsesscort · 28-08-2010, 12:27 PM

hey guys just wondering how hard it is to do an auto to manual conversion on a mk2 2.0L engine..??? anything major needing changing or something that can be solved by some backyard mechanics?

Les · 28-08-2010, 07:18 PM

Tim, Just had a look on a couple of Escorts in the back yard. The floor pan seems pretty much the same, you will need to get clutch peddle, cable and brackets off a manual and a manual brake pedal. I would surmise your Auto was a T bar shift? I don't recall ever seeing anything else in an Escort, the floor hole looks to be in the same place. Don't gorget to change the flywheel spigot bearing to take the front shaft or it'll slap around and stuff up.
Other than that I couldn't see anything out of the ordinary.

Someone else on here may have done this already, in 30-40 years the Escorts have been around I would think so.
Cheers,
Les

obsesscort · 28-08-2010, 07:52 PM

G'day Les,

Currently got a 1600 with a 4spd, just bought a 2000 with an auto, so have all of the required manual parts and stuff.

I guess that's a good start! :P

Les · 29-08-2010, 08:21 AM

Tim,
I guess it's a start but not sure the 1600 4 speed will fit the 2000. All the other bits should be ok. Will check comparisons shortly and let you know. Alternately someone might have already done this. Is your gearbox a top loader or linkage?
Cheers,
Les

obsesscort · 29-08-2010, 11:47 PM

Thanks Les, not too sure about the meaning of toploader/linkage though...?

Les · 30-08-2010, 08:46 PM

Does the gearbox have linkages going from the gear lever, mounted above the gearbox to the levers on the side of the gear box or does the gear shift lever fit into the top of the rear gearbox housing?
Les

obsesscort · 04-09-2010, 03:25 PM

Hey Les,

Still haven't got this far in the conversion have yet to pick up the 2.0L etc...

Puzzlescort · 06-09-2010, 07:02 AM

Tim

this is real easy if I understand you have a manual escort now & have brought a 2L with an Auto on it....
pull the Auto off, get a 2L manual flywheel, get it skimmed a bit, inset a spigot bush in the end of the crank, get a 2L bell housing, the gearbox if it is original from your van being a MK2 will be the same
You will need a 2lt rad and insert the 2 ltr rad cut out to allow the radiator to move forward
A few wiring mods will need to be done as well for starter etc

obsesscort · 06-09-2010, 06:28 PM

Thanks guys, I'm sure there will be more questions once I get the donk home!

mike77cos · 17-09-2010, 06:54 PM

I'm looking to do the same conversion possibly, I have looked and I think the tube that the clutch cable runs through will need to be fabricated

Grandmaspec · 28-09-2010, 11:11 AM

this is real easy with a standard escort 4 spd, did it a couple years ago. the auto tunnel is bigger than the 4 spd manual so you wont have any problems fitting it, the hole for the shifter lines up perfectly with the one from the auto shifter so that's not a problem. You will need to fabricate a new gearbox cross member because the tunnel is bigger and the mounting point is slightly off. you can make one out of the old auto mount and a few extra bits of steel, if you're in perth Race Tune has the template for one which they lent us. The prop shaft fits off the auto but try get a one piece because the bearings go pretty easily in the two piece. Just remember to reinforce the firewall where the clutch cable comes through because you can rip the whole cable through. Have a look at a manual escort and copy their reinforcement or if you've got a parts car just cut it out of that one and weld it on. we were 15 and pretty clueless when we did this but it's still running strong so it's a bit of a no brainer, Good luck.

whooligan · 15-10-2010, 10:37 PM

I think the question is more about the motor rather than an auto conversion. As I read it you want to fit a 2lt into your 1600 van, no? Theres no difference btween a 2lt out of an auto and one out of a manual other than the spiggot bearing in the crank and the use of a flywheel and clutch as opposed to a drive plate and torque convertor on the auto.
If you've already got a manual in your car, you just have to ditch the 1600, and fit the 2.0lt. Relocate the alternator wiring and exhaust and swap the radiator. The 2lts had a different radiator, but I ran my old 2lt coupe with the old 1600 radiator and it was fine. The mounts are different on the 2lts as well otherwise you'll scrape the sump on the early Mk2s (crossmembers are slightly different)
2lt and 1600 Gearboxes are Identical. There are early and late ones but ratios are the same. Clutch plate is smaller on the 1600 but you can use them on a 2lt. I did for years.