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