Is it possible to convert 530 to 540? +More

[Badshift]

Hi,

I am looking for a 1995 540i/6sp in burgundy color. I can't find one. However if I buy a 1995 525i or 530i in burgundy, can I do an engine swap and tranny swap to convert the original car into a true 540i? Or is the suspension different as well?

Thanks.

[632 Regal]

would have to change the control units for the trans/engine dme, probably the wiring harness as well. The 540 also came with a beefier rear differential housing.

[DueyT]

Hi,

I am looking for a 1995 540i/6sp in burgundy color. I can't find one. However if I buy a 1995 525i or 530i in burgundy, can I do an engine swap and tranny swap to convert the original car into a true 540i? Or is the suspension different as well?

Thanks.

Badshift, a 530 (94/95) could be used as a donor, but not realistically with a 525 or 535 (or 518/520...any "6"). The power brake booster, master cylinder and the powersteering is very different on the V-8's than the 6's.

Regarding the running gear, 540i/6's have big brakes (thicker fronts, and the rears are ventilated and almost as big as 525/535 fronts!), and different diff (2.93open and different splines on the input shaft). So, you would have smaller brakes and you would need to either replace the diff and driveshaft, or leave the diff and modify the existing driveshaft for length to hook up with the guibo and transmission.

You may want to ask DrewZ about his modifcation to make his 540i6T... certainly could tell you about what it took to convert.

Cheers,
Duey

[632 Regal]

Badshift, a 530 (94/95) could be used as a donor, but not realistically with a 525 or 535 (or 518/520...any "6"). The power brake booster, master cylinder and the powersteering is very different on the V-8's than the 6's.

Regarding the running gear, 540i/6's have big brakes (thicker fronts, and the rears are ventilated and almost as big as 525/535 fronts!), and different diff (2.93open and different splines on the input shaft). So, you would have smaller brakes and you would need to either replace the diff and driveshaft, or leave the diff and modify the existing driveshaft for length to hook up with the guibo and transmission.

You may want to ask DrewZ about his modifcation to make his 540i6T... certainly could tell you about what it took to convert.

Cheers,
Duey

[Badshift]

too much work. I think I will just have to wait for the exact car that I am looking for in stock form.

Thanks.

[DrewZ]

The 3.0/5-speed to 4.0/6-speed requires replacement of the driveshaft, diff & half-shafts as well. My own swap ended up costing about $5k net after selling off a lot of the donor car's parts & the 3.0l/automatic. That number doesn't include all the hours spent taking apart the parts car, responding to emails, packing & shipping, etc. . . Since "regular" 540i 6-speed are relatively easy to find, the cost of the swap wouldn't be worth it, IMO. You should be able to find a suitable '95 540i/6 for less than $5k over what your 530 is worth.

Drew Zacharda
6-speed Touring

Badshift, a 530 (94/95) could be used as a donor, but not realistically with a 525 or 535 (or 518/520...any "6"). The power brake booster, master cylinder and the powersteering is very different on the V-8's than the 6's.

Regarding the running gear, 540i/6's have big brakes (thicker fronts, and the rears are ventilated and almost as big as 525/535 fronts!), and different diff (2.93open and different splines on the input shaft). So, you would have smaller brakes and you would need to either replace the diff and driveshaft, or leave the diff and modify the existing driveshaft for length to hook up with the guibo and transmission.

You may want to ask DrewZ about his modifcation to make his 540i6T... certainly could tell you about what it took to convert.

Cheers,
Duey