Keisler TKO500 Installation

[Sinister68]

Anyone else install the auto-to-manual conversion and have to notch the transmission crossmember to clear the shifter nub?      

This is not a simple installation as you can see.

[THE CHARGER PUNK]

ouch

[BrianShaughnessy]

Wow...  um...  I had to remove the shifter nub box to get mine up in place.   It's 2 bolts.   Then I put it back on once in place. 

Other than that... for this 

Shift handle doesn't fit transmission nub:

They should have sent an offset adapter.  They stick does NOT bolt up to the trans.   And just to be sure... the TKO600 takes 3/8"-16 bolts to mount the adapter to trans and adapter to handle.   The TKO500 "SHOULD" take 5/16"-18 bolts...   I know that because they sent me the wrong offset adapter 3 times 2 years ago. 

What size headers you got that have so little clearance? 

[Charger-Bodie]

the only problem i had on that list when i installed my tko600 was the wrong speedo cable everything else went smooth with no cearance ploblems or any other problems really i think it was a nice kit

[471_Magnum]

I had some minor challenges with mine. Nothing like you are experiencing.

You've obviously got some incorrect parts.

TO bearing is wrong. There should not be a clearance issue.

Shifter handle requires a dogleg adaptor.

Clutch aligment tool is wrong. SHould be a #48.

Can't really blame them on the header clearance. That part comes with the territory.

They sent me the wrong sheetmetal as well.

They also sent me the wrong speedo cable, which was actually worked because I had factory cruise. Dumb luck on that one.

I know it's frustrating, but if you give them the chance to make it right, they will.

Unfortunately, that doesn't recover the weekend that you've probably just pissed away. Been there, done that.

[Rolling_Thunder]

Hell...    looks like Keisler screwes another guys weekend plans...      hey man just remember  "6-8 hour installation"...         

[is_it_EVER_done?]

I don't know what the differences are between the TKO 500 and 600, but my 600 auto to manual kit fit fine with only the cutting of a section of the floor and welding in the new sheetmetal for clearance (just as was advertised as necessary). My patch that was included was flat and was a "bend to fit" design, so no problems with that. No notching of the torsion bar crossmember was necessary.

I did have to send back a couple of small parts that were not for my application, but Keisler was easy to deal with, and quickly sent the correct ones, though this WOULD definitely be an annoyance if you were in the middle of the swap on a car that you planned to be driving as soon as you finished.

The headers, as someone else stated, is just a header issue that comes with the territory. It looks like you will be able to easily fix that problem with a bit of grinding on the bellhousing. I went with the Lakewood scatershield, and knew from years of experience with them, that I would have to modify my headers to fit.

The clutch disk rivet is an issue with the clutch manufacturer. Can't you just pry it out? I don't think it's really fair to blame Keisler for the clutch manufacturers mistake, but I'm sure they will make it right if you can't fix it yourself.

I didn't like the shift handle adapter, so I just cut down the shifter, drilled new bolt holes so that the shifter came out of the console in the right place and bolted directly to the transmission shift nub. This was a personal preference, and not a Keisler issue. They even took back the adapter and refunded the cost.

My suggestion is to call them and get a technician to go over each of your issues. Send your tech the pictures you have. I always found them to be quite helpfull.

[Sinister68]

It all boils down to poor quality control.  They could easily eliminate most problems by simply double-checking the parts they send.  Thus far, my perception of Keisler is that they get your money first, then toss a bunch of miscellaneous parts together and let you sort it out; i.e. "We'll sell you a kit, you must make it fit!"

So far this install has taken 3 weekends mainly due to the fact that I'm having to wait to send parts back and forth.  The kit originally cost a little under $5K, but with all of the postal charges, its now over $5K.  (If there was a way to factor in the headache factor, the cost would probably be double!)

The headers are TTI step headers for the Indy SR's.  I'll try removing the shift nub box; Its the only other option I have at this point without performing major surgery on my transmission tunnel/crossmember (and possibly weakening the integrity of the crossmember).

As for the loose rivet, make no mistake: it is Keisler's responsibility to ensure reliability of the parts they sell - Even if they don't produce the part!   It all goes back to quality control.  (The absolute least they should have done was to perform a visual inspection!) Additionally, seeing something like that in a $5K kit doesn't leave me with a warm fuzzy feeling about the rest of their kit.

[Rolling_Thunder]

Sinister...     I'm sorry to hear about your misfortunes...     I do agree with you 1000% - Keisler has probably the WORST quality control I have seen...     and I deal with alot of companies considering I work at a restoration shop. Personally I rip on Keisler whenever I get the chance...      last week Doug Glad (Car Craft editor) was here and I discussed Keisler issues with him....      the gist I got in return was that his boss endorses Keisler simply because they have $$$ and advertise a great deal in Car Craft as well as other mags....       There ARE other kits out there. I purchased mine from Darkhorse Performance. there is another company coming out in the near future dubbed Classic Mopar 5-speed      - - -    Keisler did not give me the warm and fuzzies either...     theur customer service was very curt and generally useless when i contacted them - so i went elsewhere.

Again - sorry about your misfortunes and I hope you get them sorted out quickly

[Sinister68]

Thanks for all the input, guys.

I'm throwing in the towel.  Even with the shifter nub out of the way, the trans is still too wide for the trans crossmember.  I can't drop the back of the engine any further without having to remove the steering center link and destroy the ball joints.  Looks like I bought a $5K paper weight.   I've never seen anything that is so difficult to install.      

[Rolling_Thunder]

Sinister...     My recomendation...     send EVERYTHING back to Keisler and let them know why - then pruchase a kit from Darkhorse or wait until CM5S comes around.

[is_it_EVER_done?]

Keisler aside, I'm wondering if you might have some other problem as your transmission sits back at least two inches further than mine. I even have the containment plate that fits between the scattershield and engine block, which puts the trans back another quarter inch or so.

Mine is a 69, but your 68 should be the same. I just can't figure out why your trans sits so far back unless the TKO 500 is longer than the 600.

I only bring it up because I'd hate to see you send everything back then end up with the same problem from another vendor.

[Sinister68]

If my 727 had fitment problems, I'd agree, but my 727 fits perfectly in the chassis; No alignment or clearance issues.  My Charger was built 9/28 of, I believe, 1967.