TheSamba.com :: View topic - Full write-up on converting Vanagon from auto to manual

Sat Aug 04, 2018 1:21 pm

My guess is towards the end of the vanagon era, they may have been using up whatever was laying in inventory.

Now what I did not take into account, is my carpet has a square notch in it where the autostick cover attached. Will need to deal with that at some point.

Thanks for documenting this. It's a good reference.

Thu Aug 16, 2018 6:28 am

funny that this thread got resurrected just a few days ago,
so I figure I'll post it here.

Im at the point of wiring for the backup lights. which wire is it?
the post below asked the question, but was never answered.

Im assuming the the single wire with the connection, but in the descriptions everyone is saying to run the "wires" to the rear... so now Im not sure.

thanks all.

Westendwulf wrote: Hello all,

For those that have done the auto to manual conversion ..... could you look at this photo and give me a heads up on which wires to mod/extend to the manual trans reverse light switch .......

B/W and Brown run through a couple lights that illuminated the auto shifter console

Blue/W (molex con.) ??????

Please forgive me before you respond ........ I'm a wiring GENIUS :oops: [/img]

Chris

Thu Aug 16, 2018 7:30 am

Hello, the black wire with the blue tracer is the power lead to the backup lights. If you add power to that connection, the backup lights should light.

So at a minimum, you'd need to run power to the backup light switch on the transmission on one connector and extend the blue black wire to the other pin on the backup light switch.

I can't say specifically for your van, but you should be able to find a connector for the backup lights in the wire box l/f of engine compartment and key on power, so no need to run wires from the front of the van if that makes sense.

Sun Aug 19, 2018 6:27 am

MarkWard wrote:
I can't say specifically for your van, but you should be able to find a connector for the backup lights in the wire box l/f of engine compartment and key on power, so no need to run wires from the front of the van if that makes sense.

thanks for this mark. didn't even think of that.
sure enough. black/blue wire runs back to the "black box" at engine.
it's a lone yellow connector which splits off to two wires (also black/blue)
to the reverse lights. so I can now keep it all wired up back there.
clean.

thanks!

Sun Aug 19, 2018 6:35 am

Glad to help. Felt bad about muddying up this thread. In my project I need to relocate wiring for backup lights, fuel pump, fuel sender, and to bypass neutral safety switch.

Mon Nov 18, 2019 7:25 am

Hi all,

I'm thinking about purchasing a 1990 Vanagon that currently has a 2.2L Subaru that was swapped some time ago. It has an automatic transmission, but the transmission has some fault that prevents it from driving.

Long story short, what all would I need to complete a manual swap? I have Porsche 914 5 speed, and I could come up with your average run-of-the-mill 4 speed.

Is there anything else needed that would be different, as apposed to the factory 1.9L?

Would any of the wiring be different for this application?

Thanks.

Mon Nov 18, 2019 9:15 am

MaryvilleAirCooled wrote: Hi all,

I'm thinking about purchasing a 1990 Vanagon that currently has a 2.2L Subaru that was swapped some time ago. It has an automatic transmission, but the transmission has some fault that prevents it from driving.

Long story short, what all would I need to complete a manual swap? I have Porsche 914 5 speed, and I could come up with your average run-of-the-mill 4 speed.

Is there anything else needed that would be different, as apposed to the factory 1.9L?

Would any of the wiring be different for this application?

Thanks.

The auto trans is generally very good especially with a subaru. Is there any reason you would not just install a rebuilt auto vs swapping to manual?

Mon Nov 18, 2019 9:27 am

the 914 5speed will only fit in a vanagon when you put it in the sliding door.

think about it, where is the engine orientated to the transaxle?

MaryvilleAirCooled wrote: Hi all,

I'm thinking about purchasing a 1990 Vanagon that currently has a 2.2L Subaru that was swapped some time ago. It has an automatic transmission, but the transmission has some fault that prevents it from driving.

Long story short, what all would I need to complete a manual swap? I have Porsche 914 5 speed, and I could come up with your average run-of-the-mill 4 speed.

Is there anything else needed that would be different, as apposed to the factory 1.9L?

Would any of the wiring be different for this application?

Thanks.

Mon Nov 18, 2019 10:19 am

I think you can flip the R&P around on those for rear engine configurations. I'd also want a real engine to go along with a Porsche trans...or any trans.

Sun Feb 12, 2023 7:28 am

I am currently in the thick of this conversion using the instructions provided by original poster. I would like to add a couple of tips to help other’s avoid “gotcha’s” that I encountered.
Make sure donor tranny has the clutch lever arm VW part number 251-141-713b. Without it you are screwed as they have been extinct for 15 years. Also there is a difference between above part number for diesel and petrol versions.
If using later style master and slave cylinders with banjo fittings, the hole in the “firewall” is too small to fit either end of a soft banjo hydraulic hose. I opened up the hole with a hole saw.
I did invest in aftermarket repair kits for each joint in the shift linkage, from rebuilding shifter mechanism to all the joints and boots on the shafts for peace of mind.
Also taking opportunity to rationalize all the accessory wiring cobbled on over the years, adding sound dampening behind the dash, replacing brake booster and getting a new gas tank and replacing fuel lines from a-z. Plus cleaning the grime from behind the dash and in the engine compartment and redoing the insulation for hot foot syndrome. And wirebrushing and painting shift rods and parts. It’s nicer to work with clean parts even though it takes time. This is a job you don’t want to hurry. Also, have a zen like patience while waiting for parts. Hard to anticipate ahead what you need until you are in the thick of it.

Sun Feb 12, 2023 11:04 am

Where did you find a brand new Vanagon brake booster?
I've been working on adapting something to offer up for the Vanagon, but plug and play is better...

Sun Feb 12, 2023 12:17 pm

Earlier in the summer, Ken at Van-Again in New Jersey put out an email saying he had a limited supply, knowing I-was going to do this project, I snagged one. Give him a call or leave a voicemail to see if he has any left.

Thu Nov 30, 2023 11:09 pm

I'm almost finished with my manual conversion and wanted to clear up any confusion (that I had) about the reverse switch wiring.

When you pull down the wiring from the auto selector box you have five wires. Two larger diameter red wires, a small brown, black w/ blue tracer, and a black with grey tracer wire. Connect the two larger red ones together. The brown is just a ground so tuck it back up into the loom. The black with blue tracer is indeed the wire that leads to the reverse lights in the junction box. The black with grey tracer comes out of the D16 position of the fuse box and through fuse 15 (reverse lights). This is 12v when the ignition is on.

So. Run both the black/blue wire and the black/grey wire back to your reverse switch on your manual tranny and that's it, you're done. Plus you're still using the proper fuse position if anything comes up down the road and you need to troubleshoot.