Several questions on 6 speed conversion

[yaofeng]

I put the clutch pedal in over the weekend. I was told the existing brake/clutch can stay. It is not the case. The auto brake/clutch bracket does not have the seat (welded on the bracket) for the pivoting spring at the top of the clutch pedal. So the bracket has to be replaced.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3242.jpg
The brake/clutch pedal bracket between the auto and 6 speed are otherwise identical except the auto doesn't have a seat for the pivoting spring on the clutch pedal.

After punching out the preformed hole on the firewall for the clutch master, I found I need a rubber plug to seal it. My feet will be very cold in winter driving if I don't do it. Anyone know where to find the plug on the ETK? If I can't find it I'll seal it with RTV but I'd rather get the correct plug.

Sunday I started removing the drive shafts and the propeller shaft in preparation for lowering the differential to install that for the 6 speed. Took me six hours just to remove 30 bolts. My impact didn't do a thing. I had to loosen them first with a 1/2" drive breaker bar before removing the allen bolts with the air ratchet.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3251.jpg

it took so long because I stripped two 10 mm allen bolt on the differential side, one on each drive shaft. I spent closed to three hours cutting the allen bolt head off using the Dremal cutting wheel.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3252.jpg

But my next question is while struggling under the car on my back, I saw the fuel line severely rusted. Last year when I did the 525 I saw the same thing. Why does BMW not use plastic coated fuel and brake lines? My SAAB's all have them. They are pristine, no rust whatsoever. I am now debating whether to replace the fuel lines. The ETK doesn't tell me what diameter it is. Anyone knows? Has anyone replaced the fuel line before?

[Yaninnya]

After punching out the preformed hole on the firewall for the clutch master, I found I need a rubber plug to seal it. My feet will be very cold in winter driving if I don't do it. Anyone know where to find the plug on the ETK?
I think here:
http://www.realoem.com/bmw/showparts.do?model=HE51&mospid=47384&btnr=51_1765&hg=51&fg=80
I know that you ask a long time ago but information can be usefull for other forum members.
Jan
BTW: Any chances for thread about conversion?

[yaofeng]

Thanks. I found that before. But gave up not knowing which plug to pick. My project is not done yet. But I took pictures along the way. I am now fixing the rusted fuel lines. I'll put the final drive and rear drive shafts back up after the fuel line is done.

[yaofeng]

I think here:
http://www.realoem.com/bmw/showparts.do?model=HE51&mospid=47384&btnr=51_1765&hg=51&fg=80
I know that you ask a long time ago but information can be usefull for other forum members.
Jan
BTW: Any chances for thread about conversion?

Thanks again for the reminder. I think I found the plug for the clutch master cylinder looking at the ETK more closely and comparing it to the hole where the master cylinder sticks out. Item #28 is the only oblong plug with a slit which matches what's shown in the picture. I need to order from the dealer in my next batch of parts.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3280.jpg
The clutch master cylinder sticks out from the firewall through an elliptical hole.

[Yaninnya]

The clutch master cylinder sticks out from the firewall through an elliptical hole.
Today I was removeing from my E30 (318i '87) cluch master cylinder (plastic pipe which connecting ruber hose from fluid tank and master cylinder suddenly broke. I still don't know why) and it looks exactly the same in E30. I think that you need another grommet for hose from fluid tank.
Jan

[yaofeng]

Today I was removeing from my E30 (318i '87) cluch master cylinder (plastic pipe which connecting ruber hose from fluid tank and master cylinder suddenly broke. I still don't know why) and it looks exactly the same in E30. I think that you need another grommet for hose from fluid tank.
Jan

You are right. The fabric braided rubber hose goes from the clutch fluid reservoir through the firewall to the cabin. Mine was plugged with a rubber plug since it was an auto. I simply cut a hole through the plug to feed the hose in.

You probably can tell from the picture I just took in the dark the miserable weather in New Jersey continues from last weekend.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3283.jpg

[Yaninnya]

I'm now in Poland for feew days so I will ask in BMW dealership in which I was working for a long time for the part number of the clutch master cylinder grommet.
Jan

[Yaninnya]

The part number of this grommet is 21 52 1 156 082. And I was right that in E30 it is the same:
http://www.realoem.com/bmw/partxref.do?part=21521156082&showus=on&showeur=on
Jan