old manule tranny on 1996 318 help
I have done this in a '68 Dart, a 360 Magnum with a 4 speed, and I can give you all the details you'd ever want to do it.
This is going to be a long post, so relax.
List of parts you'll need to start:
Bellhousing from a 1989 through 1991 D-100/150 that was mated to an A-535 5 speed. THIS IS THE ONLY STOCK MOPAR BELLHOUSING THAT BOLTS AN 833 TO A SMALLBLOCK WITH A 153 TOOTH FLYWHEEL FOR 11 CLUTCH!!! Magnum stick flywheels are 153 tooth only.
Flywheel from a 1992 through 2003 1500/2500 w/318 (5.2)
STICK crank sensor from 3.9, 5.2 or 5.9. it must match the era of wiring (92-'95 OR '96-'02)
Wiring to correlate to the computer you decide to use.
The automatic wiring WILL work with the stick sensor, just modify the connector plug to make it plug in.
The wiring to both plugs are the same color codes for auto or stick, the factory just adds a "stopper" in the plug to make it unfriendly to work with.
If you intend to use a 4 speed, the bearing retainer o.d. on the '89-'91 D-150 is the larger diameter, 5.125 (I think that's right), like an overdrive 833 from the '70s.
Facts lesson:
The 833 4 speed trans. case comes with 2 bearing sizes, a small 307 bearing and a larger 308 bearing.
There are 5 23 spline a-833 bearing retainers that are possible.
1. 307 bearing, small bell pilot, small bolt pattern, used '64-'73 on 3 and 4 speeds w/23 spline input, small block only w/70-74 B&E bodies.
2. 307 bearing, medium bell pilot, small bolt pattern, used in '68 and '69 b bodies only, w/23 spline input.
3. 307 bearing, Large bell pilot, small bolt pattern, usually found on '73-'80 3 speeds, w/ 6 cylinder in A, B, F bodies and trucks or vans, OR 1974 and 1975 small block A bodies w/23 spline input, same outer diameter as description 5.
4. 308 bearing, medium bell pilot, large bolt pattern, used in '70-'74 383/400 23 spline B&E body only.
5. 308 bearing, Large bell pilot, large bolt pattern, 23 spline primarily found on overdrive 833s from 1975 through 1987.
What all this means is that if you want to use the D-150 bellhousing with an earlier 4 speed 833, not an overdrive, you need to procure the bearing retainer in description 3.
If you want to use an 833 OVERDRIVE, you use what's on it already.
Are you still with me? :D
The prescribed bellhousing will necessitate some floor mods at the lower firewall, for the hydraulic slave cylinder to clear, but it's the best fit without going totally aftermarket, you will need to go with a hydraulic clutch master set-up.
You will also have to notch the bellhousing to clear the crank sensor, as this bell was never used with a Magnum engine from the factory.
The bolt pattern is nearly perfect for an 833, 1/2 a bolt hole from perfect.
The bottom right bolt hole would need to be plugged and re-drilled and tapped to the correct dimensions.
What I've told you so far will at least get the transmission bolted to the engine.
Honestly, an 3 speed automatic would be by far easier and a lot less mods would need to be done, but I found the challenge, and success, of doing the 4 speed far more rewarding.
Any Mopar 5 speed into an A body absolutely requires structural mods!!!
Mark.