530iT 5 speed swap thread

[Julien]

Hey guys,
Got all my parts together to do a five speed swap on my e34 (from Ross on here and BMAparts)

At roughly 1pm...

A little bitchin' got that huge/heavy exhaust out (broke two bolts though :-( )

My guibo was in STELLAR shape (I don't know how the car still moved)

Driveshaft came out surprizingly easy..



Now to the transmission. I have removed 8 bolts and have completely and utterly stripped the **** out of one. It sits about at 10pm on the transmission and I'm at a complete loss of where to go from now apart from pulling the motor out (if that happens the same motor isn't going back in *hint-hint*. I can barely get my hands on it and thats about it. Any ideas?

Thanks,
Julien

[repenttokyo]

Really brave to do it outside - that's dedication to getting things done on time!

[Julien]

No way I can drill it out because of where it sits. Tranny is sitting off its mounts on a jack right now.. no more room there. I'll go buy one of those stripped bolt removers, does anyone have a picture so I can see what they look like? I'm guessing a place like northern tool would carry it.

Thanks,
Julien

[bad_manners_god]

http://cgi.ebay.ca/NEW-SNAP-ON-TOOLS...2em118Q2el1247

[Julien]

More updates:
Since the machine shop had not resurfaced my flywheel I went ahead and started on the interior bits.
Shifter pannel:

Then continued on to the pedal box.. whatabitch. Used a sawzall to get the "safety" bolt out

Also worked out the hydraulic lines (and installed the clutch fluid tank):

and at 8pm eastern time... it looked like this :-)


More tomorrow
Julien

[yaofeng]

Don't know how the 5 speed is different from the 6 speed. When I did mine, I need to add the reverse light switch connector since it was absent on the 5 speed auto but the switch is on the 6 speed gear box. The connector is a generic Bosch two prong connector. I made use of one I pulled from a 94 SAAB 9000 I parted a few years ago.



The green and blue wires go to the reverse light switch on the gear box, if I remember correctly.

[Julien]

Day 3:
Went to the clutch and brake specialist today to pick up my flywheel. He tried many different methods to resurfacing it but in the end nothing worked. So i brough it home and did some cleaning of my own:

after using the die grinder with a special end i got this result:

i also soften the edges on my clutch with the diegrinder so it seat itself better in the existing ridges (per clutch man's instructions)

[Julien]

After being happy wih those results I went and tried to attach my flywheel with the special (read: $50) tool I got the from the stealer... but it was the wrong size: AARRRRRRRRRGGGHHH :-/
So I tried to find another tool that would work locally.. Advance had the torx50 socket as part of a kit, so I bought that. Didn't fit so I took out the diegrinder again to make it smaller.
End result:

Got the flywheel+clutch In.. But am worried about the amount of torque I got on the bolts since Ross told me they (the torx bits) are weak and will snap.. hit it with a heavy impact wrench for about 5 secs each + red loctite. That *Should* do it.

I then took the tranny out of it's crate.. cleaned her up, changed the fluid, put on new tranny mounts and cleaned up some of the linkage.

[Julien]

At this point in time I noticed I was missing the shift carrier If you have a 530i/5speed parts car, PM me asap!.. and it started raining so I had a break.
After that I got inspired and got the ole tranny in der

That's it for today!

More to come.
Julien

[Julien]

Was a delay in the progress because i was missing my shifer carrier.. so i made one:

Plans

home depot parts:

Finished product:

gary likes:

Shift is notchy & tight. I like :-) even if it is only a temporary fix.
and my slave cylinder crapped out inside the bellhousing of the gearbox as I was trying to bleed it...
Problem turned out to be the little nylon cup & clip that hold in the fork that touches the throwout bearing. $7 later, a quick rebuild of the slave cyl, and removing the tranny got everything fixed. Car seems to run well. Feels slow, but I'm not getting to hard on it either.

-next wiring up clutch pedal switch to start car & for cruise..


Julien