2003 Auto to Manual swap

Ok, thanks for letting me know about the sway bar nut. I did buy a rear main seal (as well as the Lisle seal puller) and do plan on changing that. I finished cleaning up the rusted areas and treated them with the metal prep spray. The next step in my plan is to apply the POR15 to the rusted areas, and while that dries, I’ll clean up the control arms and hopefully get that sway bar link nut out of there. I also need to go buy a press so I can remove the control arm bushings.

Seeing the underside of your truck (I’m so jealous at the lack of rust) reminded me of a question I wanted to ask here. I bought a set of headers from the same guy who sold me the transmission. My plan was to have a local speed shop do that install sometime over the summer. After I finished the auto-to-manual conversion and sorted out any bugs. But since I have so much stuff out of the truck now, I was wondering if I should just do it myself. These are the headers, but I don’t have any gaskets for them.

 

Yeah it would be pretty easy to install them yourself with no transmission in the way. The crossover is really the only tricky part, but you can get to it from behind the engine now.
It looks like the downpipe was cut at the first cat though, so you would need to have a flange added there or weld an intermediate pipe on to attach to the rest of your exhaust.

 

Thanks. I looked up what this kit came with new and it appears you always had to do come level of fabrication/welding. Here’s what it looked like new:

 

Ah, the “choose your own adventure” exhaust kit. Who is the manufacturer?

 

JBA headers by Pertronix. I reached out to them to see if I could just buy a new Y-pipe but they said they don’t make that kit anymore. I can still buy the full kit because there is some left in inventory but I don’t need the headers and crossover.

 

So I finished up my POR15 part of the project. At least for now. There are other places I want to coat, but they can wait.

 

It won’t win Concours at Pebble Beach, but hopefully helps with the NJ rust

 

I’m going to replace the power steering lines as well as the front differential breather tubes. All because of the severe rust.

Tomorrow I’ll take a stab at removing the stock crossover pipe and the exhaust manifolds. Is there any tips/tricks to this?

 

Looking good. Did you do the rear main seal while you’re in there?

No real tricks with the exhaust, just a pain in the ass, especially the cross over. I’d be tempted just to cut it from the back since you can get to it.

 

I am going to do rear main seal. May tackle they tomorrow. Do most folks just cut the crossover out?

 

I didn’t, just finagled it out of there. I think installation of the new one was more of a pain. You won’t really know until you’re in there doing it, but it will certainly help to have access from the back with the tranny out.

 

I don’t think people cut these exhausts out. You’ll want to soak all of the bolts in PB Blaster for a hot minute though. Also, you might want new exhaust manifold studs while you’re in there.

 

I got the rear main seal carrier out and removed the old seal. I cleaned up the carrier and the block. As far as the bead of gasket material, do I only insert it in the grooves or run it around the whole perimeter?

 

Interesting, the FSM doesn’t mention it. Did you just clean the old stuff out of the groove or scrape it off the flat mating surface as well?

 

There was definitely some gasket material on the mating surface, especially along the bottom. I installed my seal dry but now I see your manual and it says to install it with grease.

 

Right there with ya. Interested to hear how difficult it is to replace the power steering lines. Interested in doing that when I replace my steering rack.

 

Lol what

 

Somehow my MacBook did some weird translation!

 

funny. When I copy it as a quote it reads how I typed it:
“There was definitely some gasket material on the mating surface, especially along the bottom. I installed my seal dry but now I see your manual and it says to install with grease”

 

Getting to the little brackets that hold them in place was a bit of a pain, but overall not too bad. Of course, not having a transmission in place definitely makes it easier.