530iT 5 speed swap thread

[repenttokyo]

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

[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...
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01904.jpg
A little bitchin' got that huge/heavy exhaust out (broke two bolts though :-( )
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01905.jpg
My guibo was in STELLAR shape (I don't know how the car still moved)
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01906.jpg
Driveshaft came out surprizingly easy..
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01907.jpg


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

[bad_manners_god]

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

Get a slightly smaller socket and hammer it onto the bolt. It's an extremely tight fit.

Slap a breaker bar on it and give it a good tug.

[Julien]

Get a slightly smaller socket and hammer it onto the bolt. It's an extremely tight fit.

Slap a breaker bar on it and give it a good tug.
did that, the bolt is now completely round

[bad_manners_god]

did that, the bolt is now completely round

Vice-Grip's?

Umm.......

Drill a Hole and jam a Male Torx bit inside?

[Ross]

Try one of the stripped bolt removers or whatever they call them. They have a sharp slow helix that is supposed to grab even a round fastener. Sort of an internal easy out.
Drop the back of the trans for a little more wiggle room and use long extensions for that "long distance dedication".

[healtoeit]

Try one of the stripped bolt removers
I 2nd that.

You could also take a drill bit and cut the head off, then you would get the tranny off and you could pull it out like a stud.

[yaofeng]

Take the drive train out.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3380.jpg

[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

[e34.535i.sport]

I don't know how big these bolts are or if you could get one in but if its rounded on the outside what about a pipe wrench?

[bad_manners_god]

http://cgi.ebay.ca/NEW-SNAP-ON-TOOLS-1-4-dr-DAMAGED-BOLT-REMOVER-SOCKETS_W0QQitemZ370037713169QQihZ024QQcategoryZ20 773QQrdZ1QQssPageNameZWD1VQQcmdZViewItemQQ_trksidZ p1638Q2em118Q2el1247

[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.

http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3536.jpg

The green and blue wires go to the reverse light switch on the gear box, if I remember correctly.
http://i21.photobucket.com/albums/b274/yaofengchen/BMW_95_540/DSC_3538.jpg

[Julien]

My neighbor dougal came to the rescue with a a diegrinder
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01908.jpg
2 more bolts out, and bam!
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01909.jpg
And here she is.. a working 5hp18
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01910.jpg
More updates to come!! Picking up the resurfaced flywheel+tacos now

[byeyou]

nice.... i just finishd mine a month ago i swap engine & manual trans.... it's fun to drive manual touring....

[Julien]

More updates:
Since the machine shop had not resurfaced my flywheel I went ahead and started on the interior bits.
Shifter pannel:
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01911.jpg
Then continued on to the pedal box.. whatabitch. Used a sawzall to get the "safety" bolt out
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01912.jpg
Also worked out the hydraulic lines (and installed the clutch fluid tank):
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01913.jpg
and at 8pm eastern time... it looked like this :-)
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01914.jpg

More tomorrow
Julien

[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:
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01915.jpg
after using the die grinder with a special end i got this result:
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01917.jpg
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)
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01918.jpg

[Julien]

http://i291.photobucket.com/albums/ll305/eurojulien/DSC01919.jpg
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:
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01920.jpg
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.
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01921.jpg
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.
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01923.jpg

[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
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01924.jpg
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
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01926.jpg
home depot parts:
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01925.jpg
Finished product:
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01927.jpg
gary likes:
http://i291.photobucket.com/albums/ll305/eurojulien/DSC01929.jpg
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..

cheers
Julien

[bimmerd00d]

http://i291.photobucket.com/albums/ll305/eurojulien/DSC01906.jpg
My guibo was in STELLAR shape (I don't know how the car still moved)


lightweight mod?


http://i291.photobucket.com/albums/ll305/eurojulien/DSC01926.jpg

does anyone see something other than a shiftrod in this pic? http://smiliesftw.com/x/bowrofl.gif (http://smiliesftw.com)