Originally Posted by
lowell
Trevor, relatively easy job to do. No fabrication involved. Change the pedal cluster, install clutch hydraulics and shifter, swap transmission and driveshaft. Electrics are easy -- jump a few wires, optionally change the starter relay to a jumper plug, and run reverse switch wiring from the transmission up to the neutral position switch harness connector. B40 cars use the same differential input shaft, so a junkyard manual driveshaft should bolt in, but I don't know the difference in length between the 5 and 6 speeds.
Three things on 540s: 1) you need a special torx bit to install the factory dual mass flywheel -- it has a special tool part number, don't know it off the top of my head, 2) removing the transmission heat exchanger will be the most difficult part of the job, and you may ruin the (expensive) lines and cooler in the process, not that you need them again, 3) there's a manifold on the back of the engine that delivers coolant to the heat exchanger -- it will have to be replaced with the part for factory manual cars (no holes for the cooler) or rig up a way of blocking the pipes. It's difficult to get to when the car's together, so do it for keeps the first time around.
The E34 540 can use any E34/E39 6 speed, but you may need a custom driveshaft depending on what you get. The 6 speeds are cheap these days. They can't be rebuilt -- no parts available for them and they break. Having said that, I just sold one with 35k mile on it for a grand, which is a deal.
No need to get the parts for the rear coolant manifold. Just loop a piece of coolant hose between the two openings. The 6 speed flywheel is fastened to the block by nine T55 bolts, IIRC. Get the long torx bits from Auto Zone.
'01 540it, 6/01
'03 325i 5 speed, 9/02
'10 535ix. 9/09
'10 mini 6 speed
'15 mini countryman 6 speed