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Well, I think I've got the BW35 working to an acceptable degree again, at least to the point where I'm comfortable driving it around the city. I may continue to play with the throttle valve cable and cam, which requires dropping the pan again (ugh). But, I would say the ordeal has sort of proven that I better start developing a plan for what to do when it is totally kaput, which might occur in the not so distant future. I'd much appreciate any input or advice anyone has to offer concerning the following options.
This is a hobby car for me, not a daily driver. The car has character and a great story, and myself and my family have grown attached to it, so the "sell it and buy a manual" option is one I'd like to leave off the table for the time being (not to mention the problems associated with selling a car with a mostly-functioning transmission that nobody wants to service). I'm currently unemployed, which means I have more free time than I care to admit.
Replace with rebuilt BW35
I've found an online vendor selling rebuild BW35 units. Cost is $1200 (ouch). Pros would be ease of installation and limited modification. Cons would be cost, still having a life-sucking automatic, and I very well could end up in the same position in the not so distant future.
Replace with M41/OD
Probably the easiest "upgrade". I figure cost would be in the ballpark of 50% of the rebuilt BW35. Pros would be more fun to drive, and potentially increased reliability. Cons would be chasing parts (pedals, trans, bellhousing, yadda, yadda), having to modify the tunnel to gain the needed foot room, and the increased labor and time compared to the rebuilt BW35.
Replace with M410/OD
There is a fellow brickboarder offering a M410 with the B18/B20 bellhousing, and the OD unit. Pros would be the beefier tranny, and getting the bellhousing/trans/OD with minimal searching. Cons would be needing to find a cable pedal setup for the M410 bellhousing (harder to find than the hydraulic ones?), and then being locked into using only an M410 down the road (harder to find/service than an M40 or M41?).
Replace with T5
Apparently the automatic trans tunnel is large enough to accommodate the T5 conversion, but then you still have the problem of needing more foot room with the third pedal. Pros would be durability, and the plentiful parts/service availability. Cons would be cost, probably in the neighborhood of the rebuilt BW35 or higher, and again the fabrication and labor component.
The biggest turn off for me with any of the manual swaps is not the cost or manual labor, but the time/effort chasing down potentially obscure parts from many sources. If I could get a trans/OD/bell/shifter/pedals all from one (or even two) places I'd be much more inclined to go that direction, but as of yet have had no luck with that locally.
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