2002 Acura TL Type S Automatic to Manual Transmission Swap

The 2002 Acura TL Type S automatic to manual transmission swap involves converting the factory automatic transmission to a manual transmission for improved driving performance and control. This comprehensive guide covers the required parts, step-by-step installation process, wiring modifications, clutch system integration, and post-installation calibration. Below are key sections for preparation, parts list, installation steps, wiring, testing, and troubleshooting.

Required Parts and Tools

Essential components: Manual transmission assembly, clutch kit, flywheel, pedal assembly, shifter components, hydraulic lines, and ECU modifications.

Pre-Installation Preparation

Gather all necessary parts and tools. Ensure vehicle is properly supported.

1. Disconnect battery: Remove negative terminal for safety.
2. Drain fluids: Drain transmission fluid and coolant as necessary.
3. Remove components: Remove exhaust system, drive shaft, and heat shields for access.
4. Label connections: Label all electrical connectors and hydraulic lines for reassembly.

WARNING! Vehicle must be securely supported on jack stands. Use proper lifting equipment.

Transmission Removal Process

Remove automatic transmission to prepare for manual installation.

1. Disconnect linkages: Remove shift cable and throttle cable connections.
2. Remove torque converter: Unbolt torque converter from flex plate.
3. Support engine: Use engine support fixture to hold engine in place.
4. Remove mounting bolts: Remove all transmission-to-engine bolts.
5. Lower transmission: Carefully lower transmission from vehicle.

CAUTION! Transmission is heavy; use transmission jack and assistant.

Manual Transmission Installation

Install manual transmission and related components.

1. Install flywheel: Mount and torque flywheel to specification.
2. Install clutch: Align and install clutch disc and pressure plate.
3. Mount transmission: Raise manual transmission into position and secure to engine.
4. Install drive shaft: Connect manual transmission compatible drive shaft.
5. Install starter: Mount manual transmission compatible starter motor.

Tip: Use alignment tool for proper clutch disc positioning.

Clutch System Setup

Install and bleed hydraulic clutch system.

• Master Cylinder: Install in driver footwell and connect to pedal.
• Slave Cylinder: Mount on transmission bellhousing.
• Hydraulic Lines: Route and connect clutch lines between components.
• Bleeding: Properly bleed system to remove air bubbles.
• Pedal Adjustment: Set proper pedal height and free play.

Wiring and ECU Modifications

Modify electrical system for manual transmission operation.

ECU Programming: Reprogram factory ECU or install manual transmission ECU to disable automatic transmission codes and enable manual operation.

Wiring: Bypass neutral safety switch, connect reverse light switch, modify vehicle speed sensor wiring, install clutch pedal position switch.

Hydraulic Line Installation

Install and route clutch hydraulic system.

1. Mount master cylinder: Secure to firewall with proper brackets.
2. Route lines: Install hydraulic line from master to slave cylinder.
3. Connect fittings: Ensure all connections are tight and properly sealed.
4. Bleed system: Remove air from hydraulic system for proper operation.

Tip: Use DOT 4 brake fluid for clutch hydraulic system.

Shifter Assembly

Install manual shifter mechanism and linkages.

1. Mount shifter base: Install shifter assembly to transmission.
2. Connect linkages: Attach shift cables or rods to transmission.
3. Install shift knob: Attach shift knob and boot assembly.
4. Adjust shifting: Set proper shift linkage alignment for smooth operation.
5. Test shifting: Verify all gears engage properly before final assembly.

WARNING! Ensure shift linkage is properly adjusted to prevent gear damage.

Testing and Calibration

Final testing and calibration of manual transmission system.

Initial Start: Start engine with clutch depressed. Gear Engagement: Test all gear positions. Clutch Operation: Verify proper clutch engagement and disengagement. Road Test: Perform test drive to check shifting performance and transmission operation.

Common Issues and Solutions

Professional Assistance: Consult certified Acura technician for complex electrical issues.

Resources: Acura service manuals; online forums for specific technical guidance.