'96 VR6 - Auto to Manual [Build]

[camhaz]

I used my original starter with the shorter bolts due to the thinner bell housing on the manual and the different front mount.

I also used that vortex thread, but chose to go down the full loom path as I had some issues with the auto wiring.

[MilkIsYum]

I pulled off most of the front end today, getting closer to ripping out the transmission. The parts I'm waiting on (see page 1 list) got sent from the states today.



I sourced a head liner that was from a MK3 with a sunroof. It needs to be re-lined though.

Also, my strut spring clamps are too bulky and don't allow me to clamp the spring tight enough to get my strut top mount back on. Does anyone in Melbourne have some I could come and use? (Thanks!)

[MilkIsYum]

I pulled out the starter motor from my donor and my golf. There's an extra 'rod' on the starter from the manual one, as well as significantly different bolt sizes.

Left = Manual, Right = Auto




Started some prep for the auto/manual swap. Installing a new heater core as well.

Before:



After: (Removed the grime and the wipers + wiper motor)



Took apart the dash as well:

[Red9N3gti]

Good work mate!

[Silver dub]

Looking forward to seeing your progress with this as i'm tackling the same thing (Converting an Auto VR6 to Manual and putting into my Manual CL).

[MilkIsYum]

Looking forward to seeing your progress with this as i'm tackling the same thing (Converting an Auto VR6 to Manual and putting into my Manual CL).

Cheers! Do you have a build thread?


I pulled out the heater core yesterday and now I'm cleaning through the heater box and repairing the blend door foam with aluminium ducting tape.

Going to try and find some wiring loom tape as well to re-wrap my cables, I've pulled off all the deteriorating foam that they were covered in. It was falling apart just by looking at it.

[BurgundyMk3]

Want to come and do my blend door? I'll pay in beer

[HaydEn]

Da fuq is a blend door

[BurgundyMk3]

Da fuq is a blend door

Its a door covered in foam that keeps the hot air out when you want cold air con. And I'm guessing bit keeps the cold air out when you want some warm air
It decintergrates and you see it fly out your vents when you turn the fan on.

[MilkIsYum]

Here's one with the foam falling off of it. It's meant to cover the whole thing.




When you're swapping the air from hot to cold with the dial it's shifting the 'door' to output from the AC instead of flowing through the heater core and putting out hot air.


I just finished putting in the new heater core, such a woeful job! I'm almost looking forward to putting the dash back together in comparison ha.

Made new foam gaskets for all the different vents and used some adhesive foam to restore the blend doors. Vacuumed all of the foam out of the heater box as well. Hopefully none will spit back at my face.

Going to tape up all of the dash loom tomorrow and figure out the vacuum lines. The heater core had already been bypassed when I bought the car so I didn't have to do much in that regard.

[Juzzpc]

Here's one with the foam falling off of it. It's meant to cover the whole thing.




When you're swapping the air from hot to cold with the dial it's shifting the 'door' to output from the AC instead of flowing through the heater core and putting out hot air.


I just finished putting in the new heater core, such a woeful job! I'm almost looking forward to putting the dash back together in comparison ha.

Made new foam gaskets for all the different vents and used some adhesive foam to restore the blend doors. Vacuumed all of the foam out of the heater box as well. Hopefully none will spit back at my face.

Going to tape up all of the dash loom tomorrow and figure out the vacuum lines. The heater core had already been bypassed when I bought the car so I didn't have to do much in that regard.

damn, come and do my heatercore lol, mine has a bypass atm too, so whats to the job just get the dash out and all that then replace heater core and plug in the hoses? how long'd it take! i'm gonna do mine soon enough!

Its a door covered in foam that keeps the hot air out when you want cold air con. And I'm guessing bit keeps the cold air out when you want some warm air
It decintergrates and you see it fly out your vents when you turn the fan on.

ohhhh so that's what all the foam stuff is that i keep pulling out of my vents..

[stefcio007]

I had one of these foam blocks hit me in the face while driving and disintegrate, was not expecting it...

[HaydEn]

Ah right. Thought you were on a different topic to heater core.

Getting heater core out takes about an hour. But that was not caring about getting it back in place in a working order.

Plethora of clips etc.

[MilkIsYum]

Today I fit my front struts after putting in new strut mounts and bearings. The car is sitting a lot higher now though, do I need to compress the springs more to reduce the height back to stock levels?

[MilkIsYum]

Chipping away at this.

Removed the rear transmission mount and the gear selector cable! Going to try and pull the auto box out during the week.

I'm busy with exams so I'm trying to get bits done here and there.