The G35 auto-to-manual swap is a popular modification among enthusiasts, offering enhanced control, performance, and driving satisfaction. It involves replacing the automatic transmission with a manual setup.
1.1 Overview of the G35 Platform
The Infiniti G35, produced from 2002 to 2008, is a rear-wheel-drive luxury sport coupe or sedan. It features the VQ35DE engine, known for its smooth power delivery and reliability. The platform is popular among enthusiasts due to its performance potential and modifiable nature. The G35 is essentially a rebadged Nissan 350Z with a more refined interior and additional features. Its automatic transmission, while convenient, often prompts enthusiasts to pursue manual swaps for enhanced driving engagement. The G35’s combination of power, handling, and affordability makes it a favorite for those seeking a balance between daily drivability and performance modification.
1.2 Benefits of Converting from Automatic to Manual
Converting the G35 from automatic to manual offers several advantages. It enhances driver engagement, providing better control and a more immersive driving experience. Manual transmissions are lighter and more fuel-efficient, reducing power loss and improving acceleration. Additionally, manual swaps can increase the car’s value among enthusiasts and reduce long-term maintenance costs. The direct connection between the driver and the vehicle fosters a more enjoyable and precise driving experience, especially for those who enjoy spirited or track driving. Overall, the conversion is a cost-effective way to elevate performance and personal satisfaction.
1.3 Challenges and Considerations
Converting the G35 from automatic to manual presents several challenges. Sourcing compatible parts, such as the rear differential and driveshaft, is essential for proper functionality. The clutch and brake pedal assembly must be retrofitted, requiring precise modifications. Additionally, the transmission and manual-specific components must align with the vehicle’s existing systems. Mechanical expertise and specialized tools are often necessary, and the process can be time-consuming. Budget constraints may arise due to the cost of parts and potential labor costs. Lastly, ensuring the swap adheres to local regulations and safety standards is crucial. Proper planning and execution are vital to avoid complications and ensure the swap’s success.
Planning and Preparation
Assessing feasibility, defining goals, and gathering tools are crucial first steps. Ensure compatibility of parts and understand the scope of modifications required for a smooth swap process.
2.1 Assessing Feasibility and Goals
Evaluate your G35’s current setup and determine if a manual swap is feasible. Consider your driving habits, performance goals, and budget. Decide whether you aim for improved performance, better control, or simply the joy of driving a manual. Research forums and community experiences to understand the scope of modifications needed. Ensure your vehicle’s engine and chassis can support the changes. Check local regulations for any legal requirements. Set realistic objectives and timelines to guide your project effectively. Understanding your goals will help prioritize steps and resources, ensuring a successful swap.
2.2 Gathering Necessary Tools and Equipment
To undertake a G35 auto-to-manual swap, you’ll need specific tools and equipment. Start with basic mechanical tools like wrenches, sockets, and screwdrivers. A transmission jack or cherry picker is essential for handling the heavy automatic unit. Jack stands and a lift or ramps will provide safe access. Specialized tools include a clutch alignment tool, pilot bearing puller, and flywheel resurfacing kit. Ensure you have a new clutch kit, flywheel, and manual transmission components ready. Additional items like gear oil, transmission mounts, and wiring harness connectors may be required. Organize all parts and tools beforehand to streamline the process and avoid delays.
2.3 Budgeting for the Swap
Budgeting for a G35 auto-to-manual swap requires careful planning. The primary expenses include the manual transmission, clutch kit, flywheel, and related hardware. Prices for a used or refurbished 6-speed manual transmission can range from $1,500 to $3,000, depending on condition. A high-quality clutch kit, including the pressure plate and flywheel, typically costs between $500 and $1,000. Additional costs may include a new driveshaft, differential compatibility adjustments, and labor if hiring a professional. Tools, such as a transmission jack or specialized wrenches, add to the budget. Overall, expect to spend between $3,000 and $6,000 for a complete swap, depending on whether you DIY or pay for labor. Plan for potential extra costs like unexpected repairs or upgrades.
Required Components for the Swap
Key components for a G35 auto-to-manual swap include a manual transmission, clutch kit, flywheel, driveshaft, and clutch pedals. These parts ensure proper functionality and performance.
3.1 Manual Transmission and Related Parts
The manual transmission is the core of the swap. A compatible 6-speed transmission, such as the CD009, is often used for the G35. It typically includes a shifter assembly and throw-out bearing. Ensure the transmission is matched with the rear differential for proper operation. Additional components like the flywheel, clutch kit, and driveshaft must be compatible with the manual setup. The transmission and related parts should be inspected for wear and replaced if necessary. Proper alignment and installation are critical to avoid mechanical issues. Using OEM or high-quality aftermarket parts ensures reliability and performance. This step lays the foundation for a successful swap, enabling precise control over the vehicle’s power delivery.
3.2 Flywheel and Clutch Kit
The flywheel and clutch kit are essential for the manual swap. A lightweight flywheel is often recommended for improved acceleration and throttle response. The clutch kit includes the clutch disc, pressure plate, and release bearing. These components must be compatible with the manual transmission and the G35’s VQ35DE engine. The flywheel bolts and pressure plate bolts should be replaced with high-strength alternatives to ensure durability. Additionally, the pilot bearing from the automatic setup must be replaced with a manual-specific pilot bearing. Proper installation and alignment of these parts are critical to avoid clutch chatter or slippage. Always use OEM or high-quality aftermarket components to ensure reliability and smooth operation. This setup ensures proper power transfer and driver engagement.
3.3 Driveshaft and Rear Differential Compatibility
When performing a manual swap, ensuring compatibility between the driveshaft and rear differential is crucial. The driveshaft from the automatic transmission may need to be shortened or replaced to accommodate the manual setup. The rear differential must also be compatible with the manual transmission’s gear ratio and torque output. In some cases, a limited-slip differential is recommended for improved traction. Proper alignment and balance of the driveshaft are essential to prevent vibrations and ensure smooth power delivery. It’s important to verify that all components are compatible with the G35’s existing drivetrain configuration to maintain optimal performance and reliability. This step requires careful measurement and precise installation.
3.4 Clutch Pedal and Brake Assembly
Installing a manual transmission requires modifying the brake assembly to accommodate the clutch pedal. The clutch pedal must be mechanically connected to the clutch master cylinder, ensuring smooth engagement. The brake pedal and clutch pedal assembly must be compatible with the manual setup, often requiring custom fabrication or retrofitting. Proper alignment and adjustment are critical to prevent interference and ensure proper functionality. The clutch master and slave cylinders must also be compatible with the new manual system. This step is essential for achieving precise control over the clutch and brakes, enhancing the driving experience. Professional assistance is recommended for this complex process to ensure safety and reliability.
3.5 Gear Oil and Lubricants
Proper lubrication is essential for the manual transmission to function smoothly. Use a high-quality GL-4 rated gear oil, specifically designed for manual transmissions, to protect the synchromesh and gears. The recommended viscosity ensures optimal performance under varying temperatures. When installing the manual transmission, drain and refill the gearbox with fresh oil to maintain cleanliness and prevent contamination. Additionally, lubricate the driveshaft and rear differential with compatible fluids to ensure seamless power transfer. Always follow the manufacturer’s specifications for fluid capacity and type to avoid damage. Proper lubrication enhances the longevity and performance of the manual setup, ensuring a smooth and responsive driving experience. Regular maintenance is crucial to uphold the system’s integrity.
Step-by-Step Swap Process
The swap involves removing the automatic transmission, installing the manual unit, and retrofitting essential components like the shifter, clutch, and pedals for seamless integration and functionality.
4.1 Removing the Automatic Transmission
Removing the automatic transmission is a critical step in the swap process. Start by draining the transmission fluid and disconnecting the battery to prevent electrical issues.
- Disconnect the transmission cooler lines and electrical connectors carefully to avoid damage.
- Remove the driveshaft and support the transmission with a jack or transmission jack.
- Unbolt the transmission mounts and crossmember, then slowly lower the transmission out of the vehicle.
- Be prepared for the transmission’s weight and ensure proper lifting equipment is used.
This step requires patience and careful execution to avoid complications.
4.2 Installing the Manual Transmission
Installing the manual transmission requires precision and care. Begin by aligning the manual transmission with the engine, ensuring compatibility with the rear differential.
- Bolt the transmission mounts and crossmember securely, following torque specifications.
- Reconnect the driveshaft, ensuring proper alignment to avoid vibration.
- Install the shifter assembly, connecting it to the transmission linkage.
- Reattach electrical connectors for reverse lights and sensors.
Double-check all connections and ensure the transmission is level before tightening all bolts.
4.3 Upgrading the Clutch and Flywheel
Upgrading the clutch and flywheel is essential for a smooth manual transmission swap. Begin by installing a high-performance clutch kit, ensuring compatibility with your G35’s manual transmission.
- Replace the stock flywheel with a lightweight or performance-oriented unit.
- Inspect and replace the pressure plate bolts for optimal grip.
- Ensure the pilot bearing is swapped from the auto to the manual setup.
Proper alignment and torque specifications are critical to prevent clutch chatter or uneven wear. This step ensures a responsive and durable clutch system for your manual G35.
4.4 Retrofitting the Shifter Assembly
Retrofitting the shifter assembly is a critical step in the manual swap process. The automatic transmission shifter must be replaced with a manual shifter assembly, ensuring compatibility with the new transmission. This involves installing the shifter mechanism, along with any necessary mounting brackets or adapters. The center console may need modification to accommodate the manual shifter. Proper alignment and adjustment of the shifter are essential for smooth gear engagement. Additionally, some enthusiasts opt for a short shifter upgrade to enhance shifting precision and reduce throw distance. This step requires careful attention to detail to ensure seamless integration with the rest of the drivetrain.
4.5 Integrating the Clutch and Brake Pedals
Integrating the clutch and brake pedals is essential for a functional manual transmission setup. The automatic brake pedal assembly must be replaced with a manual clutch and brake pedal configuration. This requires installing a clutch master cylinder, slave cylinder, and the appropriate pedal assembly. Proper alignment and adjustment ensure smooth operation. The clutch pedal’s position and feel must be optimized for driver comfort and performance. Additionally, the brake pedal may need recalibration to maintain proper braking functionality alongside the new clutch system. This integration ensures seamless interaction between the clutch and brake systems, critical for both performance and safety during driving.
Post-Installation Steps
Post-installation involves bleeding the clutch system, adjusting components, and testing the manual transmission to ensure proper functionality and performance.
5.1 Bleeding the Clutch System
Bleeding the clutch system is crucial to remove air bubbles and ensure proper hydraulic pressure. Start by opening the clutch master cylinder reservoir and adding GL4 gear oil; Use a pressure bleeder or manual bleeding kit to force fluid through the system. Begin at the slave cylinder, monitoring for air bubbles. Repeat until fluid flows cleanly without air. Finally, check the clutch pedal for firmness and proper engagement. If issues persist, inspect for leaks or blockages in the hydraulic lines; Proper bleeding ensures smooth clutch operation and prevents premature wear on components.
5.2 Adjusting the Clutch and Gearbox
After installation, adjusting the clutch and gearbox ensures optimal performance. Start by setting the clutch pedal height and free play, typically 1-2 inches from the floor. Adjust the clutch master cylinder rod to achieve proper engagement. For the gearbox, align the driveshaft with the differential, ensuring no stress on the mounts. Use spacers or adjust the crossmember if necessary. Tighten all bolts to specifications. Finally, test the system by shifting through gears and checking for smooth engagement. If grinding occurs, double-check the alignment and adjustment of components. Proper adjustment ensures smooth shifting and prevents premature wear on the transmission and clutch system.
5.3 Testing the Manual Transmission
After completing the swap, thoroughly test the manual transmission in a safe, open area. Begin by starting the car and shifting through all gears to ensure smooth engagement. Check for any grinding or unusual noises, which may indicate improper alignment or worn components. Test the clutch pedal feel, ensuring it engages and disengages properly. Drive slowly, accelerating gradually to assess smooth shifting under load. Reverse gear operation should also be tested to confirm functionality. If any issues arise, such as missed shifts or slipping, revisit the adjustment process and ensure all components are properly aligned and secured. A successful test drive confirms the swap’s success and readiness for daily use.
Common Issues and Troubleshooting
Common issues after a G35 auto-to-manual swap include gear grinding, clutch chatter, and leaks. These often stem from improper alignment, worn components, or insufficient lubrication. Addressing these promptly ensures reliability and performance.
6.1 Solving Gear Grinding or Missed Shifts
Gear grinding or missed shifts after a G35 auto-to-manual swap often result from incorrect transmission or differential compatibility or improper clutch alignment. Ensure the transmission and rear differential are matched correctly, as mismatched components can cause gears to misalign. Inspect the clutch pedal assembly for proper adjustment and alignment, as misalignment can prevent the clutch from disengaging fully. Additionally, check for adequate gear oil lubrication, as insufficient lubrication can lead to grinding. If issues persist, consider consulting a professional to diagnose and rectify any installation errors. Proper alignment and compatibility are crucial for smooth shifting and longevity of the manual setup.
6.2 Addressing Clutch Chatter or Sponginess
Clutch chatter or sponginess after a G35 auto-to-manual swap can be caused by improper clutch alignment, worn or mismatched components, or incorrect flywheel installation. To resolve this, ensure the clutch kit is compatible with the flywheel and properly aligned during installation. Inspect the flywheel surface for excessive wear or warping, as this can lead to uneven clutch engagement. Additionally, verify that the pilot bearing is correctly installed and lubricated. If the issue persists, check for any loose or misaligned components in the clutch pedal assembly; Professional adjustment or replacement of faulty parts may be necessary to eliminate chatter or sponginess and restore smooth clutch operation.
6.3 Fixing Leaks or Noisy Operation
Leaks or noisy operation after a G35 auto-to-manual swap often stem from improper installation or worn components. Inspect the clutch master cylinder and slave cylinder for any signs of leakage, as these are common sources of fluid loss. Replace seals or entire units if damage is found. Noisy operation, such as grinding or whining, may indicate misaligned drivetrain components or worn bearings. Check the driveshaft and rear differential for proper alignment and balance. Additionally, ensure the gearbox mounts are securely fastened, as loose mounts can cause vibrations and noise. Addressing these issues promptly will restore smooth operation and prevent further damage to the transmission or drivetrain.
Additional Modifications for Optimal Performance
Upgrading the exhaust system, enhancing cooling systems, and improving suspension and handling can further optimize the G35’s performance after a manual swap, delivering a refined driving experience.
7.1 Upgrading the Exhaust System
Upgrading the exhaust system is a key modification to enhance performance and sound after a manual swap. Installing a high-performance muffler and catalytic converter can improve exhaust flow, reducing backpressure and increasing horsepower. A lightweight exhaust system made from materials like stainless steel or titanium is ideal for durability and performance. Additionally, upgrading to a performance-oriented exhaust manifold can further optimize engine output. Ensure the system is compatible with the manual transmission setup and complies with local noise regulations. Proper installation by a professional is recommended to maintain reliability and achieve the desired results. This upgrade complements the manual swap, delivering a more responsive and exhilarating driving experience.
7.2 Enhancing Cooling Systems
Enhancing the cooling system is crucial for maintaining optimal performance after a manual swap. Upgrading to a high-performance radiator or an aluminum radiator can improve heat dissipation, especially under increased engine load. Installing an electric cooling fan or a high-capacity radiator fan shroud can further enhance cooling efficiency. Additionally, upgrading coolant hoses to high-quality, heat-resistant materials ensures durability and reduces the risk of leaks. Consider a lightweight radiator or a performance-specific cooling kit designed for your G35’s manual setup. Proper installation and compatibility are essential to avoid overheating issues. This upgrade ensures your engine stays cool, even during spirited driving or track use, maintaining reliability and performance.
7.3 Improving Suspension and Handling
Upgrading the suspension and handling is essential for maximizing the performance of your G35 after a manual swap. Installing a high-quality coilover system or adjustable shocks can improve cornering stability and reduce body roll. Upgraded sway bars with stiffer rates can enhance agility and responsiveness. Replacing stock bushings with polyurethane or spherical bearings reduces compliance and sharpens steering feedback. Additionally, aligning the suspension with performance-oriented settings ensures optimal tire contact and handling balance. These modifications not only enhance the driving experience but also complement the manual transmission’s precise control. Properly tuned suspension ensures the car handles as intended, making the most of the manual swap’s benefits.
Legal and Safety Considerations
Ensure compliance with local regulations and safety standards during the swap. Use proper tools, follow safety protocols, and consult professionals to avoid legal issues and ensure safety.
8.1 Ensuring Compliance with Local Regulations
When performing a G35 auto-to-manual swap, it’s crucial to ensure compliance with local regulations. Check emissions standards, as manual transmissions may require recalibration. Obtain necessary approvals and inspections to avoid penalties. Ensure all modifications meet safety and legal standards, including proper documentation for the vehicle. Research local laws regarding transmission swaps and verify if any certifications are needed. Failure to comply could result in fines or registration issues. Always prioritize adherence to legal requirements to maintain roadworthiness and avoid complications.
8.2 Safety Precautions During the Swap
Ensuring safety is paramount during a G35 auto-to-manual swap. Always wear safety glasses and gloves to protect yourself from debris. Use jack stands to securely lift the vehicle, avoiding reliance on the jack alone. Properly ventilate the workspace to avoid inhaling harmful fumes. Disconnect the battery to prevent accidental engine start-ups or electrical hazards. Work in a well-lit area for clear visibility. Ensure the car is on level ground and apply the parking brake. Be cautious when handling hot components like the engine or exhaust. Never work under the influence of alcohol or drugs. Keep a fire extinguisher nearby and ensure all tools are in good condition. Safety should never be compromised during the swap process.
Community and Resource Support
The G35 community offers extensive support through forums, YouTube channels, and professional services. FDAuto44 and H&H Racing Development provide expert guidance and swap kits for seamless conversions.
9.1 Online Forums and Communities
Online forums and communities are vital resources for G35 auto-to-manual swap projects. Platforms like Nissan 350Z and G35 Enthusiast Forum, Reddit’s r/G35, and specialized Facebook groups offer extensive discussions, DIY guides, and troubleshooting tips. Many members share personal swap experiences, detailing challenges and solutions. These communities provide access to expert advice, troubleshooting, and parts recommendations. YouTube channels like H&H Racing Development and FDAuto44 also host tutorials and swap guides. Engaging with these forums helps enthusiasts stay informed, avoid common mistakes, and connect with others who have successfully completed the swap. They foster collaboration and knowledge sharing, making the swap more accessible and less intimidating for newcomers.
- Forums: Nissan 350Z and G35 Enthusiast Forum, Reddit’s r/G35
- YouTube Channels: H&H Racing Development, FDAuto44
9.2 Professional Help and Workshops
For those lacking experience or confidence, professional help and workshops specializing in G35 auto-to-manual swaps are invaluable. Experts offer comprehensive services, from transmission installation to clutch pedal setups. Shops like H&H Racing Development and FDAuto44 provide swap kits and professional installation, ensuring a clean, OEM-like result. Workshops often handle complex tasks like wiring, drivetrain alignment, and fine-tuning for optimal performance. Their expertise minimizes the risk of costly mistakes, making the process smoother and safer. Additionally, many professionals offer guidance and post-installation support, helping enthusiasts troubleshoot and maintain their newly swapped vehicles.
- Professional Shops: H&H Racing Development, FDAuto44
- Services: Transmission installation, clutch pedal setup, wiring, drivetrain alignment
- Benefits: Expertise, OEM-like finish, post-installation support
The G35 auto-to-manual swap is a rewarding yet challenging project that enhances driving experience and performance. It requires careful planning, precise execution, and sometimes professional assistance. Many enthusiasts have successfully completed the swap, achieving improved control and satisfaction. Proper preparation and adherence to guidelines ensure a smooth transition. The community and resources are vast, offering support and expert advice. While it demands time and effort, the end result is a more engaging and responsive vehicle, making the journey worthwhile for those passionate about driving.