Originally Posted by
timsrv
Swapping in a manual transmission is possible, but it's a big job in itself. If you are going to do it anyhow it would save time to do it now, but considering all that's involved, you may wish to wait. The best way to make that swap is to have a 5 speed donor van to rob parts off of. In addition to the transmission, you will need shift cables, the gear shift mount bracket and shift mechanisms. Then there's the clutch pedal with associated linkage, the clutch master cylinder and the slave cylinder. You will also need all the hydraulic plumbing, the flywheel, pressure plate, pilot bearing, throw-out bearing, clutch fork, etc. And don't forget the wire harness under the dash and in the engine compartment is different as well. Then there's the clutch safety switch and vans that weren't originally equipped with manual transmissions don't even have the mounting bracket for that under the dash. There is also the starter relay mounted in the engine compartment (manual transmissions have them, automatics don't) Then of course there will be the need for different drive shafts (both front and rear) because manual transmissions have a different length than automatics do.
Is a manual transmission swap possible? Yes it is. Is it time consuming and labor intensive? Yes it is. Is it worth it? That depends. If you pay a reputable mechanic to do the job, probably not. If you have the aptitude and desire to do yourself, then it can be a rewarding project. I have toyed with the idea myself and I will most likely do it someday. I have everything I need except the time. Even if I had the time, I wouldn't dream of tackling a job like this without a donor van, so I'd recommend you find one of those 1st, clear your plate of other projects, then tackle this mod.
FWIW, this has been done before by at least one person that I know of. A good alternative to an all-out transmission swap would be to swap your transfer case only with a 2 speed t-case from a 5 speed van. This is a pretty straight forward swap and won't take nearly the time or effort of a complete transmission change-over. Good luck with your project and please report back with your progress. If possible, please take lots of pics and post them here. Tim