My manual swap thread

[Analog]

Well the time has come to swap manual. Found a 530i/5 literally walking distance from my house.

I got the trans/clutch/flyhweel for 500 bucks. Fair price.

This is what I have/ordered.

5 speed transmission
5 speed driveshaft
clutch assembly
pedal assembly
slave and master cylinders
shift boot, knob, and surround
clutch reservior and brackets
new pilot bearing
new shifter bushings
clutch line from master to slave cylinder


My question is what am I missing? I know there has to be a few things but I don't want to miss them while I'm underway.

Where can I get some clutch hose? Will any kind from autozone do?

I will update this with more questions along the way. I currently have the steering column and auto pedal assembly hanging. Attempting to get the "irremovable" bolt out.

[attack eagle]

you mean the line from the brake reservoir to the clutch master?

I dunno how 530/540 are set up in that department with the brake master being elsewhere. no idea if they use a clutch reservoir and line, or if it is still a shared reservoir.

I know it is not a pressurized hose.

[jhower08]

New flywheel and pressure plate bolts, rear main seal, input shaft seal, output shaft seal, and that's about all I can think of right now.

[Analog]

you mean the line from the brake reservoir to the clutch master?

I dunno how 530/540 are set up in that department with the brake master being elsewhere. no idea if they use a clutch reservoir and line, or if it is still a shared reservoir.

I know it is not a pressurized hose.

Ah ok, I hoped someone would know something about this. This has been a spot of confusion for me. I'm hoping it is a shared reservior. I'll check out the 530i/5 at the junkyard when I go pick up the transmission today.

New flywheel and pressure plate bolts, rear main seal, input shaft seal, output shaft seal, and that's about all I can think of right now.

I'm not sure if I'm going to do a rear main seal yet. I think only if it's leaking. I'm afraid I might not get it seated correctly, and then I would have a leaking rear main seal

[Jcbe34]

Ah ok, I hoped someone would know something about this. This has been a spot of confusion for me. I'm hoping it is a shared reservior. I'll check out the 530i/5 at the junkyard when I go pick up the transmission today.

It's a seperate resevoir.. I'll see if I can find a pic. UUC also makes a stainless line to replace the lower rubber soft line.

Here: You can see it here right behind the power steering resevoir

VV

[HE53]

It's a seperate resevoir.. I'll see if I can find a pic. UUC also makes a stainless line to replace the lower rubber soft line.

Here: You can see it here right behind the power steering resevoir

VV

Damn.. I wanna put a seperate one on my non V8 car..

[madk0w]

Damn.. I wanna put a seperate one on my non V8 car..

Just curious, but why would you want to do that? There is no performance gains that I'm aware of with seperate ones, just one more thing to go wrong heh

[Analog]

It's a seperate resevoir.. I'll see if I can find a pic. UUC also makes a stainless line to replace the lower rubber soft line.

Here: You can see it here right behind the power steering resevoir

Ah, I see it. Thanks ALOT! I'm liking your engine cover as well. If I still had mine, I'd paint it up like that.

I'll take it off the car at the junkyard. I wasn't sure where to go next. I just got the irremovable pin out, and it was a bitch. I removed the whole steering column, and then ground on the pin with a cutting wheel for a good 5 minutes, and finished it off with an air chisel.

So at the moment, the manual pedals are just hanging there. I'm about to go pick up the parts from the junkyard. I'm getting excited to actually get under the car and get the big stuff out!

[Goathumper]

Damn.. I wanna put a seperate one on my non V8 car..

thats what i did instead of tapping the brakes. Best $8 ever spent.

[Sam Son]

I thought you were gonna go for a 6spd?

[Analog]

I thought you were gonna go for a 6spd?

Me too, but when a 5 speed turns up 45 seconds from your house, I couldn't pass it up.


Well, went to pick up the transmission. I got everything, but the place couldn't get the flywheel off

They said they needed a special tool?

Any ideas?

[HE53]

thats what i did instead of tapping the brakes. Best $8 ever spent.

Exactly what I was thinking..

[attack eagle]

don;t forget new nuts for the driveshaft/guibo.

[Analog]

don;t forget new nuts for the driveshaft/guibo

Why do I need new nuts for them? Different size?

[attack eagle]

one time use.

[Analog]

oh, thanks for the heads up!

Ordering new ones now.

[Analog]

ok, so I only need 6? Just where the guibo connects to the trans right?

Also, can I reuse the automatic driveshaft bolts?

Thanks!

[attack eagle]

and the diff side too.

You will have to take the DS out completely to remove the tranny.

Don't forget to replace the guibo, and CSB on the 'new' Driveshaft while it is out.

[jhower08]

Flywheel bolts are one time use as well, so are the pressure plate bolts. That's why I listed them when I posted earlier...

[strayts]

the place couldn't get the flywheel off

They said they needed a special tool?

Any ideas?

you have to use something to keep the flywheel from turning the engine while you wail away at the bolts (the spec on those babies is tight).



This is a pic of me installing an e28 singlemass flywheel in my 535i/5 during my e28 m5 clutch project. Ignore the smudges on the flywheel , they came off. What i did was i cut a piece of sheet metal i had lying around to size and drilled holes in it, then used the bellhousing bolts to secure it between the flywheel and bellhousing. I had to do this for removing the old flywheel as well as putting in the new one. It worked really well! Let me know how it goes.

[TheStigg]

You can use early VW beetle metal and rubber brake lines to plumb the clutch cyl's. Much cheaper than BMW. The stock BMW metal clutch line that goes thru the firewall is a bitch to deal with. You can easily bend a VW metal line to suit. I found it easiest to make an "L" shaped bend and fish it thru from underneath before bolting the master cyl in place. You pull some slack into the car and snug the flare nut and then push it thru and bolt the master cyl to the pedal frame. Then bend the line under the car to aim it in the general direction it goes to. VW metal brake line bends easily by hand without kinking.

[Analog]

^Wow thanks for that tip!

I'm about to get some.

[kalevera]

New flywheel and pressure plate bolts, rear main seal, input shaft seal, output shaft seal, and that's about all I can think of right now.

V8 dual mass FWs have built in bolts. Truth be told, the flywheel bolts are not one time use. They have threadlocker on them when new, torque to spec and use loctite on installation of used ones...works fine. Literature states that they should be replaced, but in practice, plenty of aftermarket flywheels come with a vial of loctite.

Same with the pressure plate bolts...reusable, unless the heads strip.

Me too, but when a 5 speed turns up 45 seconds from your house, I couldn't pass it up.


Well, went to pick up the transmission. I got everything, but the place couldn't get the flywheel off

They said they needed a special tool?

Any ideas?

You need a special tool. I believe snap-on sells an equivalent.

one time use.

It's common practice to reuse drive shaft hardware. I know that the FSM says that the nuts should be replaced, but I can't say that I've ever seen a tech do it (or have any issue related to not replacing the nuts).

[attack eagle]

I did reuse mine as well lowell, with loctite blue on the studs/bolts. Not knowing the OP's familiarity with wrenching, I could not unequivocally state that what i did was one hundred percent ok to follow for him.

[Analog]

I'm going to be safe and get new nuts for the driveshaft. It's hard for me to find the part # for the flywheel bolts on realoem.

I'm 18, so I don't have alot of experience when it comes to more in depth things like this, but I have been working a wrench since I could stand so it's not anything completely new. My dad is an old-pro as well which helps alot.

But really it's ok to talk down to me because I don't want to make any mistakes that may waste time or money!

Again, thanks everybody!