e34 Touring
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saturday's progress:
for the e34, adding the clutch pedal for an auto to manual conversion means swapping the entire pedal box. the column of the car goes through the box, so you have to pull it.
pull all the column wiring. everything has different connectors, so just yank em.
mark your shaft for re-insertion
the column has an 'impossible to remove' bolt with just a domed head. my solution was dremel a slot into it and use a wrench and a screw driver to break it free. i tried my small impact wrench, but even the impact grade flat head bits just snapped into little bits.
column out
auto box out, manual box with new master cylinder and replacement hex head for the impossible bolt ready to go it.
after you get the pedals in, you can do the clutch hydraulic lines. the auto car has the holes for mouting the resovoir so just bolt it on.
apparently they changed the location of the hard line to soft line bracket sometime in 93 (wtf bmw). i ended up drilling a hole in an L-bracket and just floating it where the hardline ended.
column and pedals in!
this is a jumper you need to make in replacement of the starter relay. it tells the system the car is in 'Park' and allows it to start.
the air show is going on at the lake this weekend, and we are by the airport, so I'm getting flyovers all day. pretty cool!
once i finished with the clutch hydraulics i could switch back to the transmission. flywheel, new clutch and pressure plate, and new pilot bearing installed.
the S5D 310Z. this also fits the m60b40 for the future. new input shaft seal, new selector shaft seal, new shift joint, royal purple fluid.
new pivot pin, clip and throw out bearing.
i got the trans bolted up and the slave cylinder in place, but it was too dark for pictures.
Dan
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she is alive! amazingly, got the project done 95% of the way by last night and was able to drive the car to work.
so far no issues other than that i think the amount of force needed to take the auto trans coolant hoses off the radiator must have cracked it because it is leaking coolant after the car is shut off.
sunday's progress:
transmission in! my neighbor helped me wiggle it into place. amazingly once we got the angle and levelness right, she just slid right into place.
shift linkage new parts ready to go. the parts car shift lever seemed to not be stock length. i could not for the life of my figure out what car it came from but maybe e36 m3? doesn't matter, its a slightly shorter throw than stock and it feels really nice. also adding the ZHP weighted knob and delrin front carrier bushing. there is not very much slop which I've never had before and it feels great.
shift linkage all in place.
3.23 LSD installed. brian did the blue powdercoat for me.
Manual driveshaft installed
Gave the driveshaft a new CSB, and don't forget to preload it towards the front of the car 3-5mm per the Bentley.
Auto trans computer (i think, lol) removed from the car.
after all this I put the car back down and crossed my fingers. fired her up and rolled her forward in 1st and back into place in reverse and everything seemed ok! open headers were awesome.
Cats reinstalled. Exhaust work sucks. So much time is wasted dealing with every one of the bolts being rusted/seized. O2 sensors plugged back in.
I finally figured out that heat + patience works best. Heat+breaker bars not so much. I would set up the bolts and put the torch on them and walk away for a few minutes, then I could tap out the seized bolt with a punch pretty easily. 2 of 4 done in this picture of the resonator flanges.
I still have to do some of the wiring odds and ends like connect the back up light wiring and disable the trans error message, and then put the last interior parts back on, but shes running well so far! Videos to come.
Dan
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Very nice!!
Why no rear Delrin bushing in the back of the carrier ?
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wow! congrats!
The pedal box was the biggest PITA on my manual swap, but I had my engine out of the car. Great work! It must be so much more enjoyable to drive.
thanks! so far much better. haven't given her the beans yet, the internet told me to drive easy for a little while with the new clutch. true?
Very nice!! Why no rear Delrin bushing in the back of the carrier ?
well, it was like $50 for the new OEM rear carrier, then you have to burn out the rubber bushing with a torch and press separate delrin one in. then you have to grind the tabs off the carrier to get it to fit. i just hated the idea of burning and cutting up brand new parts.
Dan
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Understandable on the hacking of new parts lol. I put the Delrin one in mine. It wasn't too bad and I didn't have to cut anything
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As long as you don't do clutch dumps or kick the bejesus out of it. I don't think you'll destroy it. (That's me reassuring myself that I can drive my car without a care in the world)
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nicely done! Glad it all went in without too many hickups. I am looking to join the touring club too once my lease it up on the jetta.
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Got the wiring done, everything worked exactly like the information I found online from other people doing the e34 5 speed swap, which was an added bonus. the 12 pin harness plug that they all spoke about was missing in my shifter area, but after pulling the entire shift console, I found it buried underneath (pain in the ass, but worth it)
all the console stuff pulled (i miss my e30, in which this would have have taken 2 minutes)
to trick the check control that the trans computer is there, you just have to ground out the gray pin in front (#10) on this 12 pin harness plug. you can pull pin #5 from the blue range switch plug that is no longer used from the auto trans shifter.
to get the reverse lights to work, here is the adapter that I made. i have the entire body harness from my parts car, so i can pull all kinds of nice factory plugs and already crimped pins.
my custom factory pin puller (take an metal extending antenna apart from an old radio, e30, etc)
i also switched out my HVAC panel with a fully working one while i was at it, and moved my ASC switch up by the fog light switch.
and the shift console all back together! used the weight zhp knob (feels great) and thats the m5 shift surround, which has great dividers so your crap doesn't slide around like the standard one.
the open blank is for a usb charging port from george graves on r3v: http://www.r3vlimited.com/board/showthread.php?t=357376 just waiting for it to arrive.
Dan
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Zhp knobs are the bees knees
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yes they are.
well i've put on about 400 miles since the install and have a bit of sad news - between sticky tires, stock suspension, and heavy chassis, I can't just spin the tires from a stop. the b30 has plenty of oomph, acceleration feels at least as fast as my m20 car, which could light them up no problem. until I change some things, no 11s for me. she still is fun as hell though!
mitch, i still plan on keeping my promise though!
Dan
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Even more reason to get a B40 in there! That M5 shift console looks great.
for sure! someday... and thanks!
Dan
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new pivot pin, clip and throw out bearing.
Awesome job and car.
What does that clip/wire do that is on the inside of the trans?
are you referring to the above picture? the clip holds the release fork lever against the pin on that side. the lever hinges from that point as the clutch slave piston pushes the other side of the lever toward the engine. most of the force on that end of the fork is forcing the lever against the pin behind it, so its just a measly clip to hold it steady.
Dan
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