2.5-16v transmission conversion
 

Is swapping out the autobox on the 2.5-16v for the Getrag 5 speed straightforward or are there some 'surprises' I should know about before getting into that kind of project?

I have the same thought in mind!! Awaiting for some opinions from you guys...

Transmission Swap
 

Saying you have transmission, flywheel, and clutch.

Repalce driveshaft (different length), brake master cylinder (if no fluid to outlet clutch master cylinder), and shifter.

Add clutch master cylinder and fluid lines.

Plug vacuum port on intake manifold leading to automatic transmission.

Disregard all remaining electrical for automatic transmission, put aside and seal.

I have all the parts needed for the swap including getrag tranny, driveshaft half, pedal assembly, slave cylinder, new clutch master cylinder. Also have clutch and flywheel. Only part not included is brake fluid reservoir, which can easily be modified to have the outlet to convert to the getrag tranny. The entire conversion parts are not available for shipping unless the price is worth the trouble for me. Located in MA.

Brake master cylinder does not have to be changed. It is only the brake fluid reservoir as the mannual tranny in 201s use brake fluid throughout the system. My conversion also includes the slave cylinder brake fluid hard line.

@AMGC -- any chance you have this together, still?

I just finished this swap successfully on my 91' 2.3l. I have no knowledge of the cosworths, but if your engine runs off a crankshaft position sensor timing instead of the distributor cap points timing, then you'll have to make sure your flywheel has segments for triggering the crankshaft position sensor. Also, the 91' automatic transmission driveshaft flanges/couplers on the transmission and differential sides are larger, probably due to it being newer/updated. Therefore, the driveshafts I gathered would bolt fine to the manual transmission, but would not fit on the differential. The differential of my 2.3l is slightly larger and different than one of a much earlier year; the cosworth might have a different driveshaft altogether as well as it for sure has a different differential than an average 190e. I kept both fronts and backs of the driveshafts for balancing purposes. Again, I am not sure how it works for the cosworth. My brake reservoir already had an uncut nipple on the side in place for the reservoir line(2ft. 5/16" unpressurized rubber DOT 3 rated brake line hose from reservoir to 5/16" double sided male fitting for clutch petal slave cylinder grommet, also the line that runs from the bottom of that cylinder out the floorboard, across the transmission to the clutch slave cylinder which I did not replace before doing my swap). The wires for the switch on the transmisisons driver side are for the reverse light switch on the shifter assembly and clutch cut out (i.e. won't start without clutch pushed in/won't start unless in park or neutral, but I just wired them together so it'll start whenever). I'm pretty sure most cosworths are on the earlier side of the W201 line and neither a 2.3-16 or 2.5-16 have a crankshaft position sensor, but I'd research it. Considering yours is a 2.5 and not a 2.3 it might have the bigger couplers and driveshaft which you'll have to account for. I would check the part numbers and whatnot just incase before you tear into it. Replacing the couplers could prevent tearing and vibrations as old rubber, in most cases, doesn't hold up to romping on. Good luck :) it's totally worth it. I grabbed at least 2 of everything before I started just incase something breaks or didn't fit.

Hi, were you able to get the driveshaft balanced? If so where did you go? Cheers