pedal box swap

[markus]

so if i decide to take the plunge and do a 5-speed swap how hard is it to take out the old pedal box and replace it with the one from the donor car? I looked online and I didnt really find a good writeup. I also have the telescoping wheel to help further complications.

I asked euro depot for a quote and the 5-speed kit is $1895 which includes all new wear items so I think thats a good idea. The 6-speed kit is nearly $3500 so thats out of the question. But the rest seems pretty straightforeward. I have a buddy who is pretty mechnically inclined so I would have some help.

[Kalevera]

9 bolts to remove, shift interlock cable to and a few harness connectors to disconnect and it will fall out.

Remove the shear bolt and bolt on the lower pedal box, no need to mess with the telescoping part.

Do a search here on threads by Mr. Project. Couple of good posts in there on it.

[shrike071]

Check here (http://forums.bimmerforums.com/forum/showthread.php?t=729157) - it's among the other topics discussed.

[markus]

doesnt look too bad. the only thing id be worried about is getting the "unmoveable" bolt out.

[shrike071]

You can grind it off like I did, or someone else suggested an air-chisel. Either way - the end result is the same!

[yaofeng]

I cut a slot on the tapered bolt head to remove it. I don't recall now I think the bolt is designed to shear off in case of a frontal impact so the steering column collpases.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3248.jpg

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3245.jpg

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3244.jpg

The auto bracket is different than the stick bracket. The auto bracket doesn't have the fixture for attaching the srpring to return the clutch pedal.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3242.jpg

[gale]

Mine also has the power adjust telescoping motor. I took one look under the dash and decided there was no way I was going to experience the aggrevation it would take to swap the entire pedal cluster assembly so I came up with a shortcut. I "cheated" and made a separate bracket to transfer the clutch pedal return spring seat to the existing automatic pedal cluster. Everything else about the manual vs. automatic pedal cluster assembly is identical. Even the tapped holes exist in the auto version to bolt the master clutch cylinder. All I had to do was remove the bolt that the pedals pivot on and transfer the the manual pedals into my auto frame. The return spring bracket fits over the stud on top and I added a self-tapping screw below. The resulting bracket is more rigid than the stock one. It's been 3-1/2 years since and still working flawlessly:

http://www.nmia.com/~dgnrg/pedal5.jpg

http://www.nmia.com/~dgnrg/pedal9.jpg

http://www.nmia.com/~dgnrg/pedal9a.jpg

[markus]

gale would u be able to make me one of those if i paid u? it seems like it would save a lot of time.

[gale]

gale would u be able to make me one of those if i paid u? it seems like it would save a lot of time.

Yeah, guess I could do that. How soon do you need it?

[markus]

oh man. not for a while thats even if i get a chance to sell this thing. if my friend dont buy it then im keeping it.

[txp135]

There's a guy in VA(bimmerforums) selling an 540i6 for parts. He had a lot of offers but last I heard he wanted to sell the whole thing in the neighborhood of $2500. Why not look for something like that, get what you need then part the rest out? I'd hate to see you settle for less than what you wanted (6 speed).

http://forums.bimmerforums.com/forum/showthread.php?t=731353&page=2

[markus]

can someone post the pics in here from bimmerofurm? im not a member there.