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US Army 19yrs and ......
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Discussion Starter · #1 · (Edited)
As the title states!

I ran across a truck last week that had 85% of everything I needed to do a 5 Speed swap on my truck. Upon inspection...... the swap is rather easy and straight forward! I will document this swap as a help to anyone that might want to do this; BUT this is not going to be a full blown "How To" because that would just take to much of my time that I need to do the swap itself!

FACTS

- The mounting points (4 studs) for the clutch pedal are already on the firewall
- The wiring for the clutch pedal is tucked up under the dash (clutch start safety and CC switch)
- The firewall is not fully punched for the Clutch master cylinder, but the first layer of the firewall is..... so its pretty easy to finish the cut out
- You will need to swap your flywheel from the AT to the MT version AND will require a dowel pin and MT pilot bearing
- You can retain your current drive shaft
- The PCM will accept a Re-flash for the conversion EDIT: I would advise you to contact @Supermodulation prior to starting to sort out the PCM issue; its not a simple flash update to go from AT to MT as I expected
- You need to drop the lower dash board lower support bar out and drop the steering column down to remove the old brake pedal and install the manual pedals (Clutch and Brake)
- GM states the flywheel bolts (flywheels to crank) are not reusable (NOTE: these bolts are $7 ea and you need 8)(SPECs Below)
- GM no longer list the clutch pressure plate to flywheel bolts (SPECs Below)
** I have been told that the AT harness will plug into the MT transmission (NOTE - The VSS sensor it a direct plug and play, the Reverse lights will need to be rewired off form the 12 pin park position unit on the side of the transmission; you'll need a T56 pigtail)
- If you need the Hydraulic Clutch line from GM, you can only get from GM if you order the Clutch Master Cylinder comes as one assembly/package
- Retain the same radiator, just drain the DEX6 when the lines are removed and plug the hole (pending solution there)
- The I4 and I5 MT flywheels are different
- There is no need to remove the starter to remove the transmission OR the flywheel/flexplate
- If you use the Energy Suspension(ES) Transmission bushing/mount (Part # 3-1108) AND have the JTR Low Pro transmission cross member, you'll need to open up the mounting point on the cross member as where the mounting points on the ES bushing/mount are slightly narrow

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UNknowns
-ALL UNK issues have been resolved as of 21NOV15
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PARTS on hand or ordered:
- 06 MA5 trans (used junkyard) $425
- 06 pedals (brake/clutch) (used junkyard) $15
- 06 clutch master cylinder/Hydraulic clutch line - (GM 24249143) $92.13
- Royal Purple 75w90 (2.5 Qts Required) 3qts = $45
- Pilot bearing (GM 12557583) $17.51
- Fly wheel dowel pin (1) (GM 11503504) $4.07
- Floor shifter boot (GM 15840127) $32.23
- new e Brake cables (GM 25830085/25830082) (CREWCAB) $54.56 / $41.28
- Steering column cover set (GM 10376748) *includes upper/lower pieces $12.37
- NEW Clutch safety start switch (GM 15101582 ) $31.30
- NEW Clutch cruise control switch (GM 22620887) $12.37
- clutch slave cylinder - Duralast (great piece, includes a new sleeve, O-ring AND hydraulic line tool) DURALAST part # 900096, $82.07
- 3.5 SPEC brand Stage 1 clutch kit, $150
- Hurst Chevy Colorado shifter kit ( Core Hurst Shifter 2004 2012 Chevy Colorado GMC Canyon Truck AR5 5 Speed MA5 | eBay )
- Wiring harness pigtails ( T56 Connector Set of 3 Backup Reverse Lockout VSS Wiring Pigtail GM LT1 LS1 | eBay )
- Xtreme Manual cluster bezel (eBay, $65)
- Flywheel to crank bolts - Fastenal, $8.89
- clutch pressure plate to flywheel bolts - Fastenal, $2.19
- New OEM shift boot/console insert (GM 15112814) $128.58
- New OEM Flywheel (GM 19177876) $185.78 NOTE if you order a new flywheel from GM, it will come with the bolts
- New OEM tail shaft seal (GM 89048306) $58.33
- New transmission mount/bushing (Energy Suspension, Part #3-1108) $26

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NEW Part numbers: The flywheels from the 2.8 and 3.5 ARE different

Flywheel 3.5 - GM Part Number 19177876, list $176.49
Flywheel 2.8 - GM Part Number 89060406, list $170.93
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Torque SPECs as required:

- Flywheel to Crank bolts (8 bolts): 30 FtLbs, then 45*
- Clutch Pressure plate to Flywheel (6 bolts): 15 FtLbs, then 45*
- Clutch Slave Cylinder (2 bolts): 71 INCH pounds
- Transmission to Engine bolts: "PENDING"

** Pilot Bearing install depth is .457" **

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Transmission wiring pin outs - Use a T56 reverse light pigtail (GRN/BRN)



The wire colors may differ, but you need to use PIN 10 and PIN 11 for your reverse signal.

 

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Premium Member
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1,795 Posts
Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

hell yes. Would love to see the harness question answered.

Then you need to integrate the 5 spd with a Hummer console :)
 

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2 timer
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1,555 Posts
Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

Are you going to need a new manual column to replace the shifter on the column of the Automatic?
 

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2,757 Posts
Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

You can just yank the automatic shifter off the column and swap the column surround to pieces from a manual truck. Same concept in the floor shift conversion how-too.
 

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maniac mechanic
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5,767 Posts
Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

I looked into it as well, seemed very straight forward. The PCM can be rewritten to run the manual as well, you just need a manual tune file to copy your vehicle info into and flash to your PCM.

I still regret bailing on doing it on my truck, but I figured the automatic is more sensible for the trails and my truck isn't driven on the road too much anymore.
 

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US Army 19yrs and ......
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45,275 Posts
Discussion Starter · #11 ·
Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

I have some pics, but I will update those over the weekends.

I'm going to be placing a few more orders this week and hopefully have everything I "need" for the swap.

Not only that, I have to wait for my buddy to finish up his swaps....... He has a RC SRT10 and a CC SRT10; he's swapping the T56 from his RC over to the CC
 

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Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

This is going to be awesome, I got the torque spec from this forum for the 04 regular cab i just swapped a 2.9 in, but so ya know what I ran into when swapping a motor from an automatic to a manual is on the crank shaft where the pilot bearing is pressed in on a manual gm put a bushing in it where the convertor snout fits into it it will need to come out so ya can put the bearing in, just so your not surprised like I was lol but good luck , I have pics in the i5/i4 engine section if ya want to see pics of what I'm talking about
 

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US Army 19yrs and ......
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45,275 Posts
Discussion Starter · #13 ·
Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

^^ Yeah link for the pics would be great. @ryhnoman

I did note the parts were different between the 2 via the diagrams i have been studying from GM. So how much of a PITA was is to remove? and did you find a trick to removing it in a timely manner?
 

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Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

What other Forum has all these upgrades? Nation has alot of firsts. Welcome to the club! I know you'll find a little more MPH and better gas mileage. The wow factor is knowing you have one more gear on most folks. Get use to saying: See Ya! :salute:
 

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Premium Member
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1,795 Posts
Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

What other Forum has all these upgrades? Nation has alot of firsts. Welcome to the club! I know you'll find a little more MPH and better gas mileage. The wow factor is knowing you have one more gear on most folks. Get use to saying: See Ya! :salute:
This forum is almighty in comparison to other forums.

#355FORLIFEYO
 

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Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

Definitely looking forward to this. Subscribed!
 

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US Army 19yrs and ......
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45,275 Posts
Discussion Starter · #18 ·

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Re: Worlds first 2004 3.5 Crewcab ZQ8 5 speed

Ahhhhh damn, you will own my dream truck! *sigh* If only mine could grow a crew cab and a 3.7L engine... God speed Jeremy and welcome to the stick club! Once you get the swap done, rev that bitch up past 3-4k RPM in 2nd or 3rd and hang on, haha! Subcribed!
 
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