Thinking about converting your 6th generation (96-00) Honda Civic from automatic to manual transmission? It’s a popular and rewarding upgrade for car enthusiasts looking for more control and engagement. To make sure your 5-speed swap goes smoothly, you’ll need to gather a specific set of Manual Car Parts. This guide breaks down every component you’ll require, ensuring you’re fully prepared for your Civic manual conversion.
Key Manual Transmission Components for Your Civic Conversion
When embarking on a manual transmission swap, acquiring the correct manual car parts is critical. Here’s a comprehensive list to guide you through sourcing everything needed for a successful 5-speed conversion on your 1996-2000 Civic.
1. 5-Speed Transmission Assembly
The heart of your conversion is the 5-speed transmission itself. For 6th Gen Civics, any D-Series SOHC hydraulic transmission from 1992-2000 models will work. There are variations to consider:
- LX/DX Transmissions: These are generally more affordable due to their longer gear ratios, which are better suited for fuel economy but offer less aggressive acceleration. Expect to find these in the $40 to $100 range.
- EX/Si Transmissions: Favored for their shorter, quicker gear ratios that enhance performance, these transmissions are typically priced higher, from $100 to $200.
Crucial Inspection: Regardless of the type, always check the transmission’s mainshaft for play. Any movement indicates a potentially problematic input shaft bearing, which is a complex repair. Online forums are often excellent marketplaces for finding used transmissions in good condition. Junkyards can be pricier as they may not reflect online market values.
2. 5-Speed Starter Motor
A 5-speed starter is another essential manual car part. Any starter from a 1992-2000 D-series 5-speed Civic will fit. The key difference between automatic and manual starters lies in the shaft length. Bench test the starter before installation to confirm its functionality.
3. Transmission Mounts and Brackets
The mounting system for a manual transmission differs significantly from an automatic. You’ll need specific 5-speed transmission mounts and brackets:
- Upper Transmission Bracket: This bracket is unique to 5-speed models.
- Front Torque Mount: Again, specific to 5-speed Civics.
- Rear T-Bracket & Frame Mount: These can be reused from your automatic setup as they are the same for both types.
eBay and online forums are good sources for these brackets. If sourcing a transmission from a junkyard, these parts might still be attached, which is ideal.
4. Shift Linkage
Shift linkages connect the transmission to your gear shifter. If your transmission doesn’t include these manual car parts, you’ll need to acquire them separately. Shift linkages from any 1992-2000 Civic with a D-Series engine will be compatible. They are commonly available, particularly in online forums, typically costing between $25 and $50.
5. Reverse and Speed Sensors
These sensors are usually included with the transmission. If not, they are relatively inexpensive and readily available for 1992-2000 D-Series Civics.
- Speed Sensor: A 3-wire plug located on the top, rear of the transmission.
- Reverse Sensor: A 2-wire plug, similar to an O2 sensor plug, located on top of the transmission, roughly in the center.
Online forums are again a good place to look for these sensors if needed, priced around $20 to $45 each.
6. Clutch Master Cylinder
The clutch master cylinder, a key part of the hydraulic clutch system, bolts to the firewall next to the brake master cylinder. You can source this manual car part from auto parts stores, online forums, or junkyards. Junkyards and forums are more budget-friendly. Ensure it’s in good working condition before purchasing. While compatibility with 92-95 Civic models is uncertain, it’s safest to look for a cylinder specifically for 96-00 Civics.
7. Clutch Slave Cylinder
Mounted directly on the transmission, the clutch slave cylinder is a relatively inexpensive new part from auto stores, around $20. Purchasing new often includes a warranty. Similar to the master cylinder, a 92-00 Civic slave cylinder should work, but for ease of ordering and fitment guarantees, specify the year of your Civic.
8. Clutch Lines
Clutch lines, including both the metal hard lines and the flexible rubber line, are necessary to connect the master and slave cylinders. Junkyards are the best place to find these manual car parts affordably. Aim to get the complete set from the master cylinder to the slave cylinder, typically around $20 from a junkyard. Inspect for rust to avoid leaks. Alternatively, you can fabricate your own lines using metal brake lines, remembering to include a section of flexible hose to accommodate engine movement.
9. 5-Speed Pedal Assembly
At minimum, you’ll need a clutch pedal from a 1992-2000 Civic. Some sources suggest 94-01 Integra pedals may also work, but this is unconfirmed. While you could modify your automatic brake pedal, replacing the entire pedal assembly is recommended. Often, a junkyard clutch pedal assembly includes the brake pedal as well. Online forums and junkyards are good sources.
10. Flywheel, Clutch, and Pressure Plate
For reliable performance, it’s best to buy a new clutch kit, which includes the clutch disc and pressure plate. You’ll also need a 5-speed flywheel.
- Clutch Kit: New kits are widely available on eBay and auto parts retailers.
- Flywheel: Source a 5-speed flywheel from junkyards or online forums.
- Flywheel Bolts: 5-speed flywheel bolts are shorter than automatic ones, so ensure you get the correct set.
- Pressure Plate Bolts: You’ll need approximately six pressure plate bolts, which are about $1 each from Honda dealerships, recommended for quality and fit.
11. Shift Boot, Shifter, and Shift Knob
These are largely cosmetic and can be chosen to your preference.
- Shift Boot: Any shift boot designed for a 1996-2000 Civic will work.
- Shifter: Choose any shifter compatible with 1992-2000 Civics.
- Shift Knob: Select any shift knob that fits 1992-2000 Civics.
Your existing center console is compatible with both automatic and manual setups, simplifying this part of the conversion.
12. Engine Control Unit (ECU)
A 5-speed ECU is essential for proper engine management after the conversion.
- 1996-1998 Civics (OBD2a): You’ll need an OBD2a 5-speed ECU.
- 1999-2000 Civics (OBD2b): You’ll need an OBD2b 5-speed ECU.
- D16Y8 VTEC Engines: Ensure the ECU is specifically for a 5-speed VTEC engine if applicable.
Alternatively, some choose to use a P28 ECU and a conversion harness, but this might not be legal in all regions.
13. Miscellaneous Items
- DOT 3 or 4 Brake Fluid: For bleeding the clutch lines. A larger bottle is advisable.
- Transmission Fluid: Options include standard 5W-30 motor oil, Honda genuine synthetic transmission fluid, or specialized fluids like Pennzoil Synchromesh.
- Cutting Tools: A sawzall or dremel with cutting discs for modifying the floor pan for shifter linkage clearance.
- Sheet Metal & Sealant: To cover the hole in the floor pan and seal against the elements.
- Axles: The original automatic axles are compatible with the 5-speed transmission.
Quick Overview of the 5-Speed Conversion Process
This is a highly simplified overview, not a detailed how-to guide. Professional guidance is recommended for those unfamiliar with automotive mechanics.
- Preparation: Drain transmission fluid, disconnect electrical plugs from the transmission, and disconnect the starter.
- Remove Automatic Transmission: Detach axles, unbolt support brackets, remove torque converter bolts, unbolt and remove the automatic transmission.
- Install Manual Components: Remove the automatic flywheel, install the 5-speed flywheel, clutch, and pressure plate. Install the 5-speed transmission, starter, and new front torque mount. Reinstall axles and refill transmission fluid.
- Shifter Installation: Remove the automatic shifter assembly, cut the windage tray from the old shift cable, drill holes for the new shift linkage, install the 5-speed shift linkage, shift boot, and shift knob.
- Wiring and ECU: Wire up reverse lights, bypass neutral safety switch for starting, replace the automatic ECU with the 5-speed ECU, and rewire the IACV if necessary.
- Final Steps: Replace interior components, start the car, and test the new manual transmission.
IACV Repinning for 3-Wire to 2-Wire Conversion
For certain models, you may need to adjust the Idle Air Control Valve (IACV) wiring. Refer to these diagrams for repinning the ECU harness:
For 96-98 OBD2a:
For 99-00 OBD2b:
Converting your Civic to a 5-speed manual is a significant project. By carefully sourcing all the necessary manual car parts and following a reliable guide, you can transform your driving experience. Remember to prioritize safety and consult professional resources if needed during your Civic manual conversion.
