From digest.v9.n1 Wed Jul 29 09:52:49 1998
From: "Taht, Georg I" <Georg.Taht_at_PSS.Boeing.com>
Date: Wed, 29 Jul 1998 09:23:37 -0700
>Subject: USA 1986 BMW 635CSi Tranny conversion from Electronic 4 speed Automatic to - 5 Speed Manual
What you are proposing to do, I have just completed on my 1987 535is.
The most difficult part about the conversion was getting the parts
together. My wife and I called just about every advertiser (wrecking
yard) in the Roundel to find a transmission. Finally found one at
Bavarian Auto Recycling in California.
Here is what you will need:
- 5 - Speed transmission from 1986 and on. Getrag 260/6 (It is
recognizable by the cooling fins on the bottom of the transmission.
Earlier cars had Getrag 265's or 260/5 transmissions.
- Driveshaft for your car. The automatic one is different. I bought
a rebuilt one and have had no problems with vibration.
- Pedal Assembly from a car that has a manual transmission
- Clutch Hydraulic Parts. Master, Slave, tubing, flex hose (this part
is about $50)
- Throttle position switch
- Shift assembly, including mounting, rod, shift lever, boot, etc.
- Flywheel, pressure plate, clutch, throwout bearing
- Exhaust hangar assembly that is supported from transmission
- Various nuts and bolts for the driveshaft and transmission
- Rubber disc (between transmission and driveshaft)
- Transmission support cross member
This represents the major parts, the rest was little hardware pieces.
You will need to do some wiring:
The new throttle position switch need to wired to the Motronic unit.
Wire in the back-up light switch
Install cruise control switch for clutch - The wiring harness connector
was already installed in my car.
Jumper the relay for the starter lock-out.
Note: I had a BMW ETM Wiring manual to help me out. (Very useful)
Cap off the cooling lines to the radiator for the automatic transmission
My total cost for the conversion was about $2400 (all parts were used
except for the clutch hydraulic parts, clutch disc, pressure plate,
throwout bearing, driveshaft, rubber disc)
Labor to do the job was about 80 man-hours
Purchase a BMW clutch alignment tool. It is worth the money!
The majority of the job is quite straight forward. I spent a lot of
time getting little things configured.
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