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260 manual conversion

Just finished doing a manual conversion on my 262C so I thought I'd post some info.
I parted out an '80 264GLE manual to get most of the parts.
I wanted it to be manual so it would be better to drive and have better fuel usage. plus the BW55 was terrible, I had considered fitting an AW71, but I'd prefer to have a manual. with the 3 speed at 110 it would rev at 3500rpm, fuel economy and acceleration were pretty bad. The car has a recently rebuilt B28E with bigger exhaust and some minor modifications, so I was happy to keep the current engine.

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Before
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Manual parts
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@Angus242164 supplied a new clutch hose
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I have a band new V6 clutch spare, but when I removed the one from the parts car it appeared to be almost new, so I decided to use it. I used the pedal box from an '89 240 since it was already removed, basically everything else came from the 264 or was bought new.
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New pressure plate bolts with T40 head
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Auto pedal box and firewall panel removed
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Also took the opportunity to fit a later brake booster, the early one worked fine but the hole for the check valve is bigger and a standard seal//valve doesn't fit.
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Manual firewall panel installed
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Pedal box fitted with new pedal covers
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Clutch master cylinder installed
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Auto removed
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Flywheel, pilot bearing, new rear main seal, and clutch installed.
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Clutch hydraulics and throw out bearing installed
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Gearbox and shiftier installed
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Clutch hose connected, not much clearance on a V6.
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Vibration dampener and OD solenoid installed
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Tailshaft installed
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After running it I realised the gearbox was sitting too high and the shiftier linkage was rubbing on the top of the tunnel. I fitted these spacers off an AW71 240 and it sits at the correct height.
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Bertone gear knob with tan leather cover, the overdrive is on the end of a wagon wiper stalk.
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Its much nicer to drive now, acceleration is better and a lot more responsive.
Next I plan to fit some bronze shiftier bushes and a slightly different leather cover
timbocarnut222Angus242164egadsOldnDecrepitbgpzfm142carnut1100nugget_940Vee_QueKlaptrap24and 5 others.

Comments

  • Great job Duncan. I can imagine it would be much better to drive, based on my experience of manual vs. auto 4-cylinder 240s. Look forward to seeing the car some day!
    DCW242
  • I remember machining that flywheel!

    Very detailed write up, it will totally transform the driving experience.
    DCW242
  • Awesome job, thanks for documenting and sharing
    DCW242
  • Vee_QueVee_Que (@Vee_Que) South Eastern suburbs Melbourne.
    Good write up. I loved my 264 after i converted it to manual in 2006.

    Does it have a bracket for the exhaust? I always lost my exhaust gaskets at the manifold to downpipe because it wasn't supported.
    DCW242Ex850R
  • DCW242Duncan (@DCW242) - point cook. victoria
    Great job Duncan. I can imagine it would be much better to drive, based on my experience of manual vs. auto 4-cylinder 240s. Look forward to seeing the car some day!

    Thanks Greg, the M46 is the same ratios as a 240 one but the V6 and 3.54 diff make it very different to drive.
    It would be good to get it to some events, lowering springs and window tinting is next.
    I remember machining that flywheel!

    Very detailed write up, it will totally transform the driving experience.

    Thanks. That was the flywheel for the 264 manual conversion, this one was freshly machined from the parts car. If I need to fit the new clutch I'll get you to do this on as well.
    Awesome job, thanks for documenting and sharing

    Thanks, I can't imagine many people have done or are planning to do this conversion but I figure it's good to document it.
    Good write up. I loved my 264 after i converted it to manual in 2006.

    Does it have a bracket for the exhaust? I always lost my exhaust gaskets at the manifold to downpipe because it wasn't supported.

    Thanks, I haven't drive it much yet but it's already a lot better, after I fit some better springs and shocks it should be really good all round.

    I don't have any manual exhaust brackets, only one auto one. the holes are in the wrong position but it looks like it wouldn't be too hard to make it fit. When I was doing this one of the studs broke off the manifold flange so I'll need to fix that first. Those gaskets still gave problems on my 264 which did have an exhaust bracket.
    egadsVee_Que
  • Ex850RSnoopy (@Ex850R) Somewhere Over the Rainbow. Melbourne.
    Great write up and pix!
    Did the donor have the quad headlights?
    Are they still available if so?
    I've wanted a set for future use on project, one day, of course!

    Loveyerwerk!
  • DCW242Duncan (@DCW242) - point cook. victoria
    Great write up and pix!
    Did the donor have the quad headlights?
    Are they still available if so?
    I've wanted a set for future use on project, one day, of course!

    Loveyerwerk!

    Thanks. It does have quad lights but I plan to use them on my 242GT, I'll let you know if I have a spare set once I've put all the best bits together.
    Vee_Que
  • Ex850RSnoopy (@Ex850R) Somewhere Over the Rainbow. Melbourne.
    Cheers, it was my intention to do my 245 78 with quads.
    Looking on USA eboy, there were a couple.
    There are real upgrades for the lamps, JW Speaker, etc...
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