I am going to change my 1996 ZR28 (noted upgrades in previous post) from a cumbersome and sometimes unpredictable automatic to a 6-speed.

Has anyone done this?
What are the trouble spots?
Any strange parts I need? I plan on buying everything from a local salvage yard. I think all I need is the pedal assembly with hydralics, trans, bellhousing, shifter assembly. What else? Pilot Bearing?

Probably also need the PCM reflashed to tell it that it's a manual transmission, center console, crossmember.

flywheel.

If you have access to the donor car, make a template of the shifter hole size and location. Get the shifter base plate, boot and M6 TQ arm mount with bolts. Look at the M6's TQ arm too. I think they were reinforced for LT1 M6 cars.

If you don't have it already, get a Factory Service manual. You will need to compare the wiring differences with the Park/Neutral safety switch, Clutch safety switch, Cruise control and Back up lights.

The cable that runs from the P/N Safety switch to the steering column, you can wire tie that "closed" and leave it there......otherwise the steering column will need to come out to remove it.

Loosen the A4's dipstick tube before you drop the tranny.
Remove the lines that run to the radiator. There are little C clips that hold these lines to the tranny.
Place the pedals against the firewall and mark your hole for the clutch cylinder before drilling/cutting.
Remove the steering shaft before trying to push the hydraulics through.

When I did this swap on my wife's 2000 Trans Am last year, I swapped out the Engine/Transmission wiring harness too. (I had the donor car sitting side by side) This may not be feasible for you and you may run into more wiring issues that I didn't.

If your a big guy.....get a little friend to help with the work under the dash. My wife helped

Give yourself PLENTY of time. at least 2 full days. Buy Beer for the end of each day

If you follow the write up at

http://www.afrashteh.com/tranny_pics/T56.htm

you shouldn't have any real trouble. I did mine over the course of a couple months in the winter. I'm VERY pleased with the results.

BTW, if you need a new clutch master cyl. with pressure line I have one for sale. 8-)

I have a used Street Twin (8,000 miles) with aluminum Flywheel that I'll sell for $500

http://www.afrashteh.com/tranny_pics/T56.htm

That's the guide I used when swapping.

Just a helpful tip... You do NOT need to drop your steering column when you swap the pedals. I don't have pics of the trick I used, so I will try my best to explain it:

Once you loosen the bolts holding the pedal assembly in place, grab the brake pedal shaft and the gas pedal shaft, and rotate the assembly counter-clockwise as much as you can. The main idea is to squeeze the gas pedal around the steering shaft. When you first look at it you'll think it's impossible... but you CAN do it, and you won't bend/break/damage anything.

I appreciate all of the tips. I will need those spares you guys mentioned you have. I will eventually get to this project. It would help if I could find someone local to pay to do it at a reasonable rate and is not guessing at what to do. I have my hands full keeping my C5 on the track. It amazingly uses up all of my spare time and cash.

I am a Big Guy and my litttle friend, aka. Mike Patterson, may help with enough persuasion.