E39 530i Touring Conversion

Jul 11, 2024

E39 530i Touring - Manual Transmission Conversion and More

Introduction

  • Converting E39 530i Touring from automatic to manual transmission.
  • Updating transmission to E46 M3 6-speed and E39 M5 limited slip differential.

Reason for Conversion

  • Original ZF 5-speed automatic: decent but problematic for high performance.
  • Issues: slow shifts, overheating, and limp mode on high-speed drives.
  • Personal preference: Love for manual transmission for better control and engagement.

Goal

  • Equip E39 with a 6-speed manual transmission and use original BMW parts.
  • Avoid custom fabrication.

Parts Used

  • Gearbox, flywheel, clutch kit: E46 M3.
  • Cross member, differential, drive shaft, shifter linkage: E39 M5.

Step-by-Step Process

Removing the Automatic Transmission

  • Disconnect shifter linkage, connectors, and oil cooler lines.
  • Transmission bolts removal (top bolts required extensions).
  • Starter detachment (issue with rusty pin in the bell housing).
  • Manual transmission removal resulted in torque converter fluid spill (cause: unbolted from transmission).

Removing the Differential and Other Components

  • Diff removal: Front bolt and two rear bolts, output shaft removal.
  • Wheel bearings replacement: used a Hazit puller tool.
  • Reduced airbag pressure for suspension adjustment.

Addressing Coolant Leak

  • Leak from Borg Warner thermostat; decided to replace with MALet thermostat.
  • Drained coolant, removed leaking thermostat and cooler.
  • Cleaned coolant-stained components.

Installing Manual Shifter and Pedals

  • Floor modification to accommodate clutch pedal.
  • Connected clutch line through factory-precise locations.
  • Wiring for clutch switch module and reusing automatic transmission wires.
  • Installed new master cylinder and pedals (brake and clutch).
  • Connected throttle pedal with adapted connector.

Transmission Install

  • Installed E46 M3 transmission (converted from SMG to manual).
  • Changed output flange to E39 M5 flange.
  • Installed rear main seal, pilot bearing, flywheel, and clutch kit.
  • Mounted shifter linkage (Rogue Engineering octane short shift lever).

Replacing Diff and Other Components

  • Cleaned and painted E39 M5 differential, replaced bushings.
  • Installed new wheel bearings and parking brake shoes.
  • Installed half-shafts and diff with appropriate modifications.

Drive Shaft and Axle Work

  • Replaced center support bearing on drive shaft.
  • Installed E39 M5 drive shaft and new shifter linkage.
  • Connected clutch line to brake fluid reservoir and bled the system.

Fluid Fill

  • Used 50/50 mix of ATF and MTF for transmission fluid.
  • Filled LSD with 75W140 oil.

Final Adjustments

  • Reinstalled suspension components and exhaust.
  • Torqued all mechanical connections.
  • Tested reverse light wiring and adjusted clutch stop.

Post-Swap Testing

  • Coded car to recognize manual transmission.
  • Successful initial trials with a working 6-speed manual.
  • Plan for future episodes includes further upgrades and increased engine power.

Note: Next episodes to cover clutch and flywheel upgrades, as well as power improvements with water intercooler installation.