4.0 + 6Spd Swap - What new parts are required?

[Panzer Captain]

Ok, so I've got a 530iT automatic. And, a complete running 540/6 rollover donor car. I'm sure you can tell what's about to take place here...

... what new parts should I put on, while I'm in the process?

Here's what I was thinking --- let me know if you think I'm missing anything:

- Engine mounts
- Tranny mounts
- Belts
- Fresh shifter parts

Obviously I will also be using a combination of the best parts from both cars to make one really good car.

[Antrieb]

Clutch, pressure plate, TO bearing
PCV plate and related parts
Guibo
Valve cover gaskets + check spark plugs. Coils should be fine.
Tranny flush
Diff fluid

Let me know if you need other help.

[pingu]

From what I've heard on this forum, the intake gaskets are notorious on the M60 for leaking and causing idle problems. Would be easier to do while you're doing everything else involved in the swap. Then again, where to draw the line?

[Panzer Captain]

From what I've heard on this forum, the intake gaskets are notorious on the M60 for leaking and causing idle problems. Would be easier to do while you're doing everything else involved in the swap. Then again, where to draw the line?

I have not yet had to replace these --- how time-consuming are they? Would it be easier with the motor out of the car? What's involved, basically?

[632 Regal]

while out of the car will save significant time, remember to do the front and back plate gaskets along with a new pcv plate.

I have not yet had to replace these --- how time-consuming are they? Would it be easier with the motor out of the car? What's involved, basically?

[MBXB]

If you're going to have the intake manifold off, you may as well check the injectors. You'll have them out anyway. Check all hoses and vac lines.

[Bin_jammin]

If you're going to have the intake manifold off, you may as well check the injectors. You'll have them out anyway. Check all hoses and vac lines.

And if you're going to take the manifolds off, you may as well change the headgaskets while you've got it out.

Actually, all joking aside, if it were me, I'd tear the motor down on a stand and throw a whole gasket set into it. I'd HATE to get the whole swap done and find out something stupid like a timing cover gasket or a rear main were leaking, and I could have changed it while it was out.

[Paul in NZ]

a lot of this makes sense,dunno about the headgaskets tho.....it would be a lot easier if the engine was on a stand.The m60 is hard on clutches so that is a must.

[Brandon J]

We did Scott's 525iT auto to a 535iT manual in one weekend with almost a dozen bimmer.info guys jumping in to do the work. Getting as many parts as you can is important for swaps. I had to purchase new parts to complete my S38 swap. Now what is nice is the fact that you are swapping in another V8 so some things will be easier.

The pedal assembly also needs to be swapped, manual tranny shifter consol and parts, if you are using the 540 diff, you need the rear subframe, perhaps half shafts too, get the brakes, new driveshaft center bearing, look for new wear parts like hoses, dog bones, plastic fasteners, various suspension pieces so it can handle the power, guibo, radiator holding clips that always break, different types of lock-tite, new exhaust bolts, washers and nuts, vacuum lines as they break easily too, new fuel hose to connect to the engine so it does not tear or leak later.

Don't forget all the wiring as reverse light switch might have a different pigtail. Save all the pigtails as you never know if one crushes and cracks or if there is a change. You can pop the wires out and swap in the unbroken or other connector. Just follow the wiring diagrams. Remove the auto tranny computer. The auto gear light in the gauge cluster might turn on and people just removed the bulb as the permanent fix. Remember to disconnect the battery before removing the cluster.

Replacing wear parts is always good and on the engine it is always easier to do so with it outside of the car. Don't forget to drop the pan and check any loose bolts, perhaps change valve gaskets at this time, rear main seal since it is accessible, manual tranny gaskets, and so forth.

The best way to do the swap is to have a laptop with the etk and tis in the same garage and have both cars next to each other. If you have to take parts before it is hauled away, get as many big expensive parts as you can. Mark the driveshaft with alignment lines so it goes in the same way it came out. Mark the hood too so you can realign it easily when putting it back.

My donor parts came from a rolled over vehicle and it is great to see others using these to keep them alive. GO HYBRID!

[Panzer Captain]

Awesome post, thanks!

How long will a clutch take, if the motor + tranny are out of the car?