Assembling a 540i, 5-Speed Manual Tranny from Parts ?

[muttley]

I'm a newbie in the market for an E34, and having read through the archives and realizing just how small the chances are of ever finding an E34 BMW with a 4 liter V8 Alusil engine block and a 5-speed manual gear-box, I couldn't help wondering how feasible it would be to purchase an E34 rolling chassis with decent bodywork, along with a manual 5-speed gearbox and a used Alusil 540 V8 motor, and then paying an indy workshop to do the assembly. Would labor charges make the job too pricey ?

I've seen non-running BMW 525i or 535i advertised for a few hundred bucks, while I've read price estimates for used 540i Alusil engines quoted at between 2 to 4 thousand USD in this forum. I've no idea how easy a 5-speed M34 gearbox could be found in Southern California where I plan to purchase and use the vehicle, so I guess my question is: Can a 540i Alusil engined E34 BMW be assembled from parts for under my budgeted 5 grand USD, and does the chassis have to be a 540i to accommodate the 4.0 liter V8, or would any E34 rolling chassis accept that donor engine without welding needed ?

Apologies if this subject has been covered in the archives, but I really did use that search button and so I hope this is not a repeat dumb question.

[liquidtiger720]

why not just go for a six speed? I don't think any of the 540's came with 5 speeds?

"Since someone asked ( and I know I looked for this all over the place before I did it! ), here is what I can come up with for all of the parts used in converting my 94 540ia to a 540i/6:

6-speed transmission (msrp ~$5k)
clutch master and slave cylinders
flywheel ( msrp ~700 )
driveshaft ( msrp ~$700-800 )
pedal cluster
shifter and linkage

This is everything I "got" from a donor car via the internet.
In addition, I was invoiced for this from the mechanic:

21 52 1 159 350 fluid hose ( $37.50 )
11 14 1 729 836 gasket ( $5.90 )
11 14 1 710 247 crankshaft seal ($52.25 )
25 11 1 221 822 (2) shift bushing ( $12.40 )
23 70 1 092 201 cross member ( $37.11 )
23 70 1 141 614 (2) trans mount ( $34.20 )
11 21 1 720 310 pilot bearing ( $18.06 )
18 21 1 178 340 (2) exhaust hanger ( $17.00 )
26 12 1 226 657 center support ( $100.20)
25 11 1 222 651 mounting ( $19.37 )
25 11 1 222 365 shift a ( $23.26 )
MTL redline ynth mtl ( $18 )

Labor for me would have been $930, which includes reprogramming the reverse lights and the passenger mirror tilt-down stuff. Alas, the tranny I bought was bad, so I had to pay another $600 for diagnosis, removal and installation of a brand new 6-speed.

I still need a shift knob and boot, too.

Hope this helps someone.

-- Will
1994 540i/6 w/Dinan catalogue."

[genphreak]

Forget it, its far too hard to do the conversion- there are many more parts on the car that are substantially different- electrics, suspension, driveline, brakes, a lot looks the same but is actually slightly different as BMW are a tad perfectionsitic unlike the shop that agrees to build it at an 'affordable' price. Better off buying them both for parts and getting a 540i that could do with some work- but was built properly in the first place. Plus you get to do the funs bits yourself. Sorry to rain on your parade, nothing is impossible most here will agree. Now come the encouragements.... Nick

[632 Regal]

one very obvious problem would be the ABS braking ststem which is just behind the front fender/bumper to allow room for the V8. Just go get a nice 540 and be done with it. A nice 540 would cost ~10-12k either its mint or you will be the one fixing it up, either way the price will be paid.

[mattyb]

absolutely agreed!

[Paul in NZ]

and a 540 would be to much for a "normal" 5 spdThe M5 and the 540 have a gearbox which my mechanic reckons is TWICE as beefy as a 535 tranny

[Kalevera]

Forget the V8, buy a 535/5 speed or an M5. Only way to own an E34. Just MHO.

best, whit