The car is a 2002 Protege' 5 and it is sitting with a 2.0L and an auto 4speed trans. I am sick of running 3000 rpms at 70mph and want to swap in a 5 Speed Manual. I am sure I need the following:
New Trans(what models will have them?)
ECM from the donor vehicle
and a clutch add on for the cab

What else will I need and how hard is it? Any companies that offer a 6 Speed manual for this car? Or just a new clutch pedal instal kit?
And most of all, is this something that I can keep under $5K?
Any recommended mods to the engine while I am in there? And not turbo, nitro, or any other bull. Its my wifes car and I don't want her to kill herself.

 

Ummm, if reducing your RPMs at 70 mph is your goal then you should probably forget the conversion. Why? My Mazda3 5-Speed runs just a hair over 3,000 RPMs at 70 mph, and if anything, I think the Protege5's 5-Speed manual transmission had even shorter gearing.

 

IIRC my '02 Protege ES 5-speed was running about 3500 RPM at 70 mph in 5th gear.

 

So, switching the trans out for a manual can sound like the wrong idea, but lets pretend I have a few ASEs and know what I'm doing.

My main goal is to spin this thing up with better gearing. Are there any tranny rebuild kits that gives a little higher 5th gear? I can find some but it may be easier to get advice, that is why I am here.

And how bout answering my first question?

 

Sorry bout being a dick, but I need info. And thank you for letting me know what extra I'm needing to do.

 

Sorry, you're probably not going to get what you're looking for here; for several reasons no less:

• Even an ASE would be challenged to perform the swap due to the number of parts and such that would need to be fabbed or welded up.
• To the best of my knowledge, there have been exactly zero members here who've performed such a swap.
• Even if you were able to perform the swap, finding a different gear set is at best unlikely as I don't believe there are any available for a Protege 5-Speed manual transmission.

 

Shipo is correct, Doug.
For a short time, now defunct, there was a company that offered a slightly taller 5th gear, but for the early 3 series 5-speeds, not the Protégé. The swap could certainly be done, but you're not liable to get out of it what you want, except a little better control and response from the direct drive over the slushbox.... slightly better mileage as well.
And my '04 3 (5-speed) runs around 3,200 in 5th @ 70 too.

I'm a dyed-in-the-wool stick driver (39yrs and counting,) so I might try doing the swap anyway. The car would certainly be more fun to drive than just throwing it in "D" and going.

Oh, and from your list, don't forget the flywheel and pilot bushing too.

 

My new 5 is a refreshing change from the Protege ES in that at 70 mph in 6th gear its turning at 2750 RPM, while the Protege was at 3500-3600 RPM at the same speed.