Hey guys! So, you're thinking about swapping out your automatic gearbox for a manual one in your trusty Proton Wira? Awesome! It's a pretty common mod, and for good reason. Manual transmissions can offer a more engaging driving experience, improved fuel efficiency in some cases, and often, a bit more pep from your engine. But, before you jump in headfirst, let's break down everything you need to know about the Wira manual conversion. We'll cover the whys, the hows, and the what-to-expects so you can make an informed decision and hopefully, have a successful project. This isn't a weekend job, mind you, it takes a bit of time, patience, and some mechanical know-how. But, the reward of rowing through the gears in your Wira? Totally worth it for a lot of enthusiasts.

Why Swap to a Manual Gearbox?

Okay, let's talk about the burning question: Why bother with a Wira manual conversion in the first place? There are several compelling reasons, depending on what you're hoping to achieve. First off, and maybe most importantly, many people find manual transmissions far more fun to drive. You're in complete control, selecting gears, rev-matching, and experiencing a more direct connection with the car. It’s a completely different feel compared to the auto. Second, manual transmissions are often more efficient than older automatic gearboxes. You might see a slight bump in your fuel economy, though the exact difference depends on your driving style and the specific transmissions involved. Third, some people believe that manual cars are generally more reliable, though this really depends on how well the car is maintained. Fewer complex components can sometimes mean fewer things to go wrong. Lastly, a manual conversion can be a great way to breathe new life into an aging Wira. If your auto gearbox is on its last legs, a manual swap could be a cheaper and more reliable option than a full automatic gearbox rebuild. Moreover, the Wira, a classic car that's still cruising on Malaysian roads, is a great choice for this conversion. The car is also available in different variants that makes it easy for the conversion to be done.

So, if you're looking for a more engaging driving experience, a potential boost in fuel economy, and maybe even a cost-effective alternative to fixing a failing automatic transmission, then a Wira manual conversion might be right up your alley. But, let's not get ahead of ourselves. There’s a bit more to consider before you get started. Keep reading!

What You'll Need: The Parts List

Alright, so you're sold on the idea and ready to dive in. Now, what do you need? A Wira manual conversion involves quite a few parts, so you'll need to gather everything before you begin. Here's a comprehensive list of what you'll typically need. Keep in mind that specific parts may vary slightly depending on your Wira's model year, engine, and any modifications you've already made.

The Essentials

• Manual Transmission: This is the heart of the conversion, obviously. You'll need a manual gearbox that's compatible with your Wira's engine. The easiest option is to source a gearbox from another Wira that came from the factory with a manual transmission. Be sure to check its condition and ask about its maintenance history. You might also be able to adapt a transmission from another Proton model, but this can require more work and custom fabrication.
• Clutch Kit: The clutch kit usually includes the clutch disc, pressure plate, and release bearing. Make sure to get a clutch kit that is designed for the manual transmission you’ve chosen and the power output of your engine. It's often a good idea to replace the clutch components when you do a gearbox swap, even if they seem okay.
• Flywheel: You'll need a flywheel designed for a manual transmission. Automatic transmissions use a different type of flywheel, so this is another crucial change.
• Clutch Cable or Hydraulic Clutch System: Depending on your Wira’s original setup, you'll either need a clutch cable or a hydraulic clutch system. If your Wira previously had a cable-operated clutch, you might be able to re-use some of the existing components. For hydraulic systems, you’ll need the master cylinder, slave cylinder, and associated lines.
• Pedal Box: You'll need the manual transmission pedal box, which includes the clutch and brake pedals. This is a direct swap for the automatic transmission pedal box, but you might need to do some minor modifications to fit it perfectly.
• Shifter Assembly: This includes the gear shifter, linkage, and any associated brackets. This is a direct swap for the automatic transmission gear selector.
• Driveshafts: Ensure that the driveshafts are suitable for the manual transmission. Sometimes, you may be able to use the existing driveshafts, but it's best to verify that they are compatible.
• ECU (Engine Control Unit): The automatic transmission ECU needs to be replaced with a manual transmission ECU. This is because the automatic transmission ECU controls the gear changes and other functions related to the transmission. If you don't swap it, your car may not run properly.

Extra Bits and Bobs

• Mounts: You might need different transmission mounts for the manual gearbox.
• Wiring Harness: If you're switching from an automatic transmission, you may need to modify or replace some of the wiring to accommodate the manual transmission components.
• Reverse Light Switch: You'll need to connect the reverse light switch to the manual gearbox to ensure your reverse lights work correctly.
• Speedometer Cable/Sensor: Depending on your Wira's model year and the type of speedometer it has, you might need to swap the speedometer cable or sensor to work with the manual transmission.
• Fluids: You'll need transmission fluid, clutch fluid (if you have a hydraulic clutch), and possibly engine oil.

Sourcing the Parts

Where do you get all this stuff? Well, you have a few options, guys. You can visit your local automotive spare part shops, especially those that specialize in Proton vehicles. You can also search online marketplaces. Sometimes, the best deals are from people parting out their Wiras.

Before you go on a shopping spree, make a detailed list of parts, compare prices, and check the condition of any used parts. Getting everything organized ahead of time will save you headaches later. Once you have all the necessary parts, you're ready to start the conversion process. Let's move on to the actual steps of the Wira manual conversion.

The Conversion Process: Step-by-Step Guide

Okay, you've gathered all your parts. Now comes the exciting (and potentially messy) part: the actual Wira manual conversion. This isn't a job for the faint of heart, but with patience, the right tools, and some careful planning, you can get it done. Always remember, safety first! Disconnect the battery and make sure you have appropriate jacks, jack stands, and safety gear. Here's a step-by-step guide to help you through the process.

Preparation and Removal

1. Preparation is Key: Start by disconnecting the battery's negative terminal to prevent any electrical mishaps. Safely raise the car and secure it with jack stands. Drain the engine oil and transmission fluid.
2. Removing the Old Gearbox: Disconnect the gear selector cable from the automatic transmission. Remove the driveshafts by disconnecting them from the transmission and the wheels. Make sure to support the engine.
3. Removing the Old Gearbox (Cont.): Disconnect any wiring connected to the transmission, such as the reverse light switch and speed sensor. Then, remove the transmission mount bolts. Support the transmission with a transmission jack or a sturdy jack, and carefully unbolt the automatic transmission from the engine. Lower the automatic transmission.

Installing the Manual Components

4. Clutch System Installation: Install the flywheel onto the engine crankshaft. Place the clutch disc and pressure plate. Make sure everything is aligned properly.
5. Pedal Box Swap: Remove the automatic transmission pedal box and install the manual transmission pedal box. Ensure all the mounting points are aligned.
6. Gearbox Installation: Carefully lift the manual transmission into place, aligning it with the engine and the clutch. Bolt the transmission to the engine. Connect the driveshafts, ensuring they are properly secured.
7. Shifter and Clutch Connections: Install the gear shifter and connect the linkage. Connect the clutch cable or install the hydraulic clutch components. Bleed the clutch system if it's hydraulic.
8. ECU and Wiring: Install the manual transmission ECU and connect all necessary wiring.
9. Finishing Up: Reconnect any wiring that was disconnected, such as the reverse light switch. Refill the transmission with the correct fluid, as well as the engine oil (if drained).

Final Steps and Checks

10. Test and Adjust: Before you lower the car, double-check all connections and make sure everything is secure. Then, cautiously start the engine.
11. Testing the Gearbox: Test all gears to make sure they engage smoothly. Check the clutch operation and make sure it engages and disengages properly.
12. Road Test: Take the car for a short test drive. Pay attention to how the clutch feels and how the transmission shifts. Check for any unusual noises or vibrations.

And there you have it, the full conversion! Congratulations on completing the Wira manual conversion.

Tips and Tricks for a Smooth Conversion

Alright, you've made it through the conversion process. Here are some extra tips and tricks to make everything go smoothly.

Research, Research, Research:

• Before you start, do your homework! Read forums, watch videos, and gather as much information as possible about the Wira manual conversion. Understanding the process beforehand will save you time and potential headaches.
• Check your Wira's specific model year and engine type to get the right parts.

Tools of the Trade

• Make sure you have all the necessary tools before you begin. This includes a good set of sockets, wrenches, screwdrivers, a jack, jack stands, and any specialty tools that might be needed for specific tasks.
• Having the right tools will make the whole process a lot easier and safer.

Organization and Labeling

• As you disassemble the car, keep everything organized. Label the parts and bolts to make it easier to reassemble later.
• Take pictures throughout the process. This can be a lifesaver if you forget where something goes.

Don't Be Afraid to Ask

• If you get stuck or have questions, don't be afraid to ask for help! There are plenty of online forums and communities dedicated to Proton Wira owners where you can get advice from experienced mechanics.
• Reaching out for help is better than making a mistake that could cost you more time and money.

Patience is a Virtue

• A Wira manual conversion is not a quick job. It can take several days or even weeks.
• Don't rush the process, and take your time to do everything correctly. Patience is key to a successful conversion.

Test Drive Thoroughly

• Before you declare victory, take the car for a thorough test drive. Make sure all the gears shift smoothly, the clutch engages and disengages properly, and there are no unusual noises or vibrations.
• This is the time to identify and fix any issues before they become major problems.

Potential Problems and How to Avoid Them

Even with the best planning, you might encounter some issues during your Wira manual conversion. Don't worry, it's all part of the process. Here are some common problems and how to tackle them.

Gearbox Won't Fit

• Problem: The manual gearbox doesn't seem to line up with the engine.
• Solution: Make sure you have the correct gearbox for your engine. Also, check for any obstructions, such as wiring harnesses or other components, that might be preventing the gearbox from fitting.

Clutch Issues

• Problem: The clutch is not disengaging properly, making it difficult to shift gears.
• Solution: Make sure the clutch is properly bled (if it's hydraulic). Adjust the clutch cable if it is cable-operated. Check the clutch components for any damage.

Wiring Problems

• Problem: The car won't start, or the lights and gauges aren't working correctly.
• Solution: Double-check all wiring connections, especially those related to the ECU and the starter motor. Make sure you have the correct ECU. Use a wiring diagram to help you identify the correct wires.

Leaks

• Problem: Oil or other fluids are leaking from the transmission or engine.
• Solution: Check all the seals and gaskets for any damage. Tighten any loose bolts or fittings. Make sure you use the correct fluids.

Vibrations

• Problem: The car is experiencing unusual vibrations after the conversion.
• Solution: Check the transmission mounts, driveshafts, and engine mounts for any damage or misalignment. Make sure the driveshafts are balanced.

Cost and Time Estimates

So, how much is this going to cost you, and how long will it take? Well, that depends on a few factors. The price of parts can vary widely, depending on whether you buy new, used, or aftermarket components. The cost of labor, if you're not doing the work yourself, will also add to the expense. Generally, it would be much cheaper if you have the skills to handle the conversion yourself.

Cost Breakdown

• Parts: The cost of parts can range from a few hundred dollars for used components to over a thousand dollars for new or high-performance parts.
• Labor: If you are paying a mechanic to do the work, expect to pay a few hundred to a thousand dollars.
• Tools: If you don't already have them, factor in the cost of tools.

Time Estimates

• DIY: If you're doing the conversion yourself, it could take anywhere from a weekend to a few weeks, depending on your experience and how much time you can dedicate to the project.
• Professional: If you have a mechanic do the work, it would depend on their schedule and the complexity of the conversion.

Budgeting

• It's always a good idea to create a budget before you start. This will help you keep track of your expenses and avoid any surprises.
• Set aside a little extra money for unexpected costs, such as additional parts or repairs.

Conclusion: Is the Wira Manual Conversion Right for You?

So, there you have it, everything you need to know about the Wira manual conversion. It’s a rewarding project that can significantly change your driving experience, but it’s not for everyone. If you're mechanically inclined, have the time and patience, and are looking for a fun project, then go for it! But, If you are unsure about your mechanical skills, or if you're not comfortable working on cars, then you might want to consider having the work done by a professional. And of course, always prioritize safety throughout the entire process.

Before you start, carefully consider all the factors involved, from the cost and time commitment to the technical challenges. If you are prepared, the Wira manual conversion can be an incredibly rewarding project that transforms your Wira into a more engaging and fun-to-drive machine. Good luck, and happy wrenching! Let me know if you have any questions, guys. I'm always happy to help! Now get out there and enjoy the road!