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Old 04-17-2009, 05:20 PM   #1
99Alero_Boy
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Stupid 5 Speed Swap

So I finally got down to denver this week to swap the built 5 speed into the alero. I picked up an 05 3400 motor out of monte carlo, looked the same, i knew some brackets had to be swapped, whatever, simple stuff. Got the flywheel and clutch bolted up, bolted the tranny up, everything looks good, drop it into car, some custom mounting brackets and everything looks great. Next morning i start on the bottom and hook everything up, A/C starter, ABS, Wiring harness, Fuel lines, etc. Get on top of the motor and the nightmares begin, 3 hours and 4 powering steering pumps later, I realize it's either yank the motor and new timing cover so I can get the power steering pump to line up, or I get a 3400 from a grand am or alero. So an hour later the motor is out and i'm very frustrated. Next morning and a 12 pack later, I got a 3400 out of a 03 grand am. New motor drops in great, mounts are good still, then when i'm hooking the fuel line back up the fpr cracks, call up GM, it's a special order and can't come until tomorrow morning two days later and a couple more minor issues aside everything is back together and the last thing to do is stab in the axles, fill with fluids, and break the clutch in.......here it comes...... ......passenger axle is a good 2 inches short, drivers is a good 2 inches long, motor is in a great position, 2 out of 4 stock motor mounts were used. Next morning, after 4 hours of searching and 2 or 3 12 packs l call up a couple local driveshaft shops, and the driveshaft shop, looks like $600 for ****ty pieces together stock axles, or $1300 for 500hp level 3 customs from the driveshaft shop, so the alero with remain in denver for a month or two until the custom driveshaft shop axles are done.... ........

On a side note, hp tuners has handled the 5 speed swap great so far and I anticipate no problems on that side, i got a set of almost brand new potenzas for my wheels for $150!! 255/40/17s in the front and 235/45/17s in the rear.

So all problems aside the alero runs again, after almost 3 years, which makes me very happy. And the new axles should be done in a month or two, and be ready for the boosted motor and fabrication of the supercharger setup!!!
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Old 04-17-2009, 07:20 PM   #2
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all I see is an array of heads pounding on walls!

Good to hear the car is coming back together. Sounds like maybe you should have checked the axle lengths before you mounted the engine and transmission though. You might have been able to avoid making custom axles. Of course, if it was too far to move and would have put the engine in a bad spot, then it was unavoidable. Maybe you should have gone for the 6spd then though. I don't recall timka having that hard a time adapting axles.

Anyway, I'll definitely be interested to see the results of another N-body manual swap. Especially since it's still pretty rare. Other than Tim, only two other people I know of have every claimed to have done it and neither ever showed any proof.
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Old 04-17-2009, 11:25 PM   #3
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Damn you're having to deal w/ alot of sh1t. G/L man.
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Old 04-18-2009, 12:31 AM   #4
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Looking forward to the completion of this as well, as I would like to see more 5 speed GA's out there
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Old 04-18-2009, 03:24 PM   #5
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I completely forgot you were working on that..

That sucks about all the headaches, atleast you had some beer to get you through it..good luck!
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Old 04-18-2009, 08:00 PM   #6
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Originally Posted by AaronGTR View Post
all I see is an array of heads pounding on walls!

Good to hear the car is coming back together. Sounds like maybe you should have checked the axle lengths before you mounted the engine and transmission though. You might have been able to avoid making custom axles. Of course, if it was too far to move and would have put the engine in a bad spot, then it was unavoidable. Maybe you should have gone for the 6spd then though. I don't recall timka having that hard a time adapting axles.

Anyway, I'll definitely be interested to see the results of another N-body manual swap. Especially since it's still pretty rare. Other than Tim, only two other people I know of have every claimed to have done it and neither ever showed any proof.
It crossed my mind before, along with the gtp tranny swap, but I would have had to get custom axles (at least on the six speed) for those probably too, since the stock axles won't hold the horsepower i'm planning on getting, the getrag I swapped in is pretty built, I had in mind the goal of 500whp daily driven. Plus I got some really rare gleason-torsen LSD, then I couldn't pass the 282 swap after that.
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Old 04-19-2009, 03:30 AM   #7
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That must be the tranny that GM used in a SEMA/show Malibu a number of years ago. It had a 5 speed with a 3400. I was always wondering which off the shelf tranny they used for it.

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Old 04-19-2009, 08:44 AM   #8
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Looking forward to the completion of this as well, as I would like to see more 5 speed GA's out there

Definitely. IDK WTF GM was thnking about by not having a 5 speed option on the GA's. They had it on the V6 Sunbirds.


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I completely forgot you were working on that..

That sucks about all the headaches, atleast you had some beer to get you through it..good luck!
Headache from the car and hangover from the beer...
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Old 04-19-2009, 11:37 AM   #9
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here's a couple pics.......

















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Old 04-19-2009, 12:20 PM   #10
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Damn that looks nice. I really would love to do this to my GA.
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Old 04-19-2009, 03:52 PM   #11
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Ya know, I may not be one of the most literate guys on the forum (full truth)..but I've always been interested in the outcome of the getrag swap on a Grand Am and still am. Really..what numbers you turn out will let me know whether I should ship my GA to europe or sell it..I reeeeeeeeeally hope I get to ship it here..
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Old 04-19-2009, 09:38 PM   #12
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My brain kinda kicked in today while helping my friend Zach (BlkGT1397) put his interior back in and I realized that... hey. I had a 3.1 V6 Sunfire w/ a 5 speed before and wondered how hard it would be to drop one in the GA.
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Oh, and I'm now house trained, so no more urinary issues to worry about.

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Old 04-24-2009, 12:39 PM   #13
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That is killer. I'd love to have a clutch in mine. I like those wheels, and the GA mirrors look great too.
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Old 04-24-2009, 06:54 PM   #14
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Definitely. IDK WTF GM was thnking about by not having a 5 speed option on the GA's. They had it on the V6 Sunbirds.

Headache from the car and hangover from the beer...
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My brain kinda kicked in today while helping my friend Zach (BlkGT1397) put his interior back in and I realized that... hey. I had a 3.1 V6 Sunfire w/ a 5 speed before and wondered how hard it would be to drop one in the GA.
. I didn't realise I posted something like this twice...
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Old 04-24-2009, 07:05 PM   #15
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im glad you didnt let all the roadblocks get you down and stop with the project. i too would like to see more manual GA's and your alero all finished up. good luck with the rest of the install.
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Old 05-12-2009, 01:41 PM   #16
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I didn't have as much trouble with axles when I did mine. I guess I was lucky. I used the axles from the base 2.4 Alero/Grand Am and the lengths were fine. Mind you, your's will probably hold up a heck of a lot longer than mine will. Especially once the boost kicks in. They take a **** kicking. LOL.

BTW, I used the tranny from the 2.2L Cavalier, 2001. 2000 - 2002 is the only year that the bellhousing bolt pattern for that tranny was the same. Someone mentioned earlier about the old tranny off the 3.1L Sunbird/Z-24 Cavaliers. These units are not as strong as the Getrag out of the newer Cavalier IMO.
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Old 05-12-2009, 02:01 PM   #17
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Or you could have done a 6 speed....

good job though
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Old 05-12-2009, 06:11 PM   #18
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I didn't have as much trouble with axles when I did mine. I guess I was lucky. I used the axles from the base 2.4 Alero/Grand Am and the lengths were fine. Mind you, your's will probably hold up a heck of a lot longer than mine will. Especially once the boost kicks in. They take a **** kicking. LOL.

BTW, I used the tranny from the 2.2L Cavalier, 2001. 2000 - 2002 is the only year that the bellhousing bolt pattern for that tranny was the same. Someone mentioned earlier about the old tranny off the 3.1L Sunbird/Z-24 Cavaliers. These units are not as strong as the Getrag out of the newer Cavalier IMO.
The tranny that I am using is the older one out of the cavaliers. They are much stronger than the new ones IMO if they are built properly like mine is. There are plenty of fiero guys with the same transmission as me pushing 400whp no problem.......there are even two with case reinforcement above 700hp.
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Old 05-13-2009, 09:59 PM   #19
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so where are the other parts comming from? (pedals, shifter, cables, etc.)
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Old 05-14-2009, 05:05 PM   #20
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so where are the other parts comming from? (pedals, shifter, cables, etc.)
the pedals, shifter, and cables along with the correct interior piece all came from GM for a 2.4 5 speed alero. The link beteen the shifter and the shift cables was kind of tricky because we needed a ball and socket link with a square bottom to fit the brackets on the tranny. I ha no idea what we were going to do until we were sitting around my buddies old chevy pickup in the shopping drinking after a long day in the shop. I looked down and for some reason that the ball part of the ball and socket joint on either side of the bed of his pickup. I unscrewed them and they work perfect.... iot was so weird that those would work......
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