Good luck! It's a bit time consuming, but not a super hard swap.

 

Thank you!

 

I finally got most parts in and decided to start one big thread and keep it here from begining to end.
Most of you here understand that this is not easy process and while I have plenty of mechanical experience, lift and tools, I am family man with full time job so this is probably going to take few months.
Also, let's please try not to turn this into SMG vs manual debate as I have quite good reasons for doing this and I spent quite a bit of time try to fix SMG and finally gave up. I simply prefer 6 speed manual over SMG.
The car is 2006 BMW M5 with 139k miles and SMG probably only needs mechatronics on top to be refreshed with new seals and possibly pistons, since everything else has been replaced.
Speaking of SMG, I have it on ebay right know so if anyone is interested, send me a message. I've refreshed quite a few things on it plus I have complete history from PO so I think it can help someone who needs a SMG.
My guidance is excellent 3 part video done by E39 Source and few excellent write ups from this forum. Due to limited avaliability of parts at the moment, my conversion will probably be little different but overall similar to others.
I basically started today and first picture is of almost all parts I'm using with few missing (arriving today):



I will update with more work and pictures this weekend...

Might as well replace the shift rod and rear output shaft seal of the 6MT while its out.

 

I agree.
I was also thinking the input shaft seal. It's not leaking but now is the time.
I did some search but could not find anything conclusive:
I decided to use M5 manual shifter parts as I thought M3 ones would be too short. I got the shifting arm and shifter lever but could not find selector rod. New is backordered and used is a unicorn.
Got the E46 on ebay for cheap and will shorten it. Even if there is a better way, I figure it's not difficult and I already got the part.
Here is the picture of test fit:

 

What’s the estimated cost including your labor hours @ $150/hour as the vast majority of owners do not have the time, skills, or equipment to undertake a project of this scale and scope

 

That is pretty much impossible question to answer fully as there are several possible approaches to this conversion. The fundamentals are the same but it all depends of parts avaliabilty at the moment and if they're used or new.
Also, it will take me probably way more many hours vs good shop who has everything ready and few guys helping each other.
So, the number of actual hours can varry quite a bit and I can't answer that part of a question.
I can tell you that I'm roughly $3k in parts and will probably end up around $4k as I may have to outsource coding since that is my weak side.
$3k includes:
Used M3 tranny $1100.
New Luk clutch and flywheel, under $700, grabbed a hell of a deal on Amazon.
New BMW manual tranny wiring $120. Also great deal and it's makes much easier to do wiring as it's plug and play on tranny side but some mods required on DME side.
The rest is mix of new and used parts: shifter components , clutch pedal components, clutch lines, etc..

 

Thanks for the feedback, it’s probably a $8K+ job all in at a specialty BMW shop assuming they would undertake the conversion, you’d really need to be committed to the conversion in my view, since the SMG transmission on the mechanical side is solid, as we know it’s on the hydraulic side that gives the headaches, good luck with the conversion!

 

No problem. I'd say you're right about the shop price.
I understand when people say SMG is great when it functions properly. But the fact is that there are so many potential issues with hydraulic side.
I gave a decent effort to fix SMG but just got tired of it.
I keep saying I will sell it but I just may keep it for a while.

 

I finally got most parts in and decided to start one big thread and keep it here from begining to end.
Most of you here understand that this is not easy process and while I have plenty of mechanical experience, lift and tools, I am family man with full time job so this is probably going to take few months.
Also, let's please try not to turn this into SMG vs manual debate as I have quite good reasons for doing this and I spent quite a bit of time try to fix SMG and finally gave up. I simply prefer 6 speed manual over SMG.
The car is 2006 BMW M5 with 139k miles and SMG probably only needs mechatronics on top to be refreshed with new seals and possibly pistons, since everything else has been replaced.
Speaking of SMG, I have it on ebay right know so if anyone is interested, send me a message. I've refreshed quite a few things on it plus I have complete history from PO so I think it can help someone who needs a SMG.
My guidance is excellent 3 part video done by E39 Source and few excellent write ups from this forum. Due to limited avaliability of parts at the moment, my conversion will probably be little different but overall similar to others.
I basically started today and first picture is of almost all parts I'm using with few missing (arriving today):



I will update with more work and pictures this weekend...

Good luck! Following this thread!

 

$8500 is absolutely worth it given the premiums 6MT cars go for. You also get more options for colour combos this way. Hmmmmm...

 

Quick update:
Haven't done much as I'm busy with installing the new floor in bonus room (I'm very excited about it, NOT!)
But still, I was able to make functional but not exactly pretty oil cooler delete and was able to sucesfully shorten and tig weld (my neighbour) cheap used E46 selector rod. The new one is NLA or backoredered and used ones are pretty much non exsistant.
It shift's like a butter now! I have the new M ZHP shifter knob and one on picture was just there to be used for testing.

 

Another quick update:

When getting all the parts I needed for conversion, I was planing to find complete used clutch pedal assembly from maybe E60 550i or whatever was direct fit.
After some checking and searching on ebay, I couldn't find anything and I ended up getting bunch of brand new genuine parts for clutch pedal assembly which was not terribly expensive anyway.
One item that was difficult to find was clutch master cylinder. BMW one is backordered and some aftermarket ones are missing the curved part on end.
After some research I realized that Dorman is actually rebadged FTE OEM made in Germany!
I got the last one in stock on RockAuto, but there are some avaliable elsewhere but for much more money.
Just thought I'd shared my discovery for future members attempting to do this. As we all know Dorman is typicaly not so great brand made in China but not this time.

RockAuto | All The Parts Your Car Will Ever Need

Auto Parts for Your Vehicle at Reliably Low Prices. Fast Online Catalog. DIY-Easy. Your Choice of Quality. Full Manufacturer Warranty.

www.rockauto.com

 

That is great info my friend! Keep up the posts I am following along!!

 

if you havent already bought a clutch line from the master cylinder to the slave cylinder you may want to consider a stainless line. Chasebays makes a stainless 1 piece line that is alot easier to route than the stock line.

 

Thanks, but I've already bought it.

 

I finally got most parts in and decided to start one big thread and keep it here from begining to end.
Most of you here understand that this is not easy process and while I have plenty of mechanical experience, lift and tools, I am family man with full time job so this is probably going to take few months.
Also, let's please try not to turn this into SMG vs manual debate as I have quite good reasons for doing this and I spent quite a bit of time try to fix SMG and finally gave up. I simply prefer 6 speed manual over SMG.
The car is 2006 BMW M5 with 139k miles and SMG probably only needs mechatronics on top to be refreshed with new seals and possibly pistons, since everything else has been replaced.
Speaking of SMG, I have it on ebay right know so if anyone is interested, send me a message. I've refreshed quite a few things on it plus I have complete history from PO so I think it can help someone who needs a SMG.
My guidance is excellent 3 part video done by E39 Source and few excellent write ups from this forum. Due to limited avaliability of parts at the moment, my conversion will probably be little different but overall similar to others.
I basically started today and first picture is of almost all parts I'm using with few missing (arriving today):



I will update with more work and pictures this weekend...

My SMG seems to be priming well and all after I installed a PLCD sensor but can’t get car to start now as it’s not sensing what gear it’s in (left in neutral prior to performing change). Either old wiring is the issue (maybe I made worse while replacing sensor) or somehow I messed up clutch slave cylinder installing the part of the sensor that feeds into to slot on clutch slave. Anyway, super worst case scenario I might need that smg trans if available still. Will know by this weekend as I’ll have a pro check it out if I can’t by then. Thanks!

 

I hate it for you, believe me.
I understand when number of people here claim they are great when working properly but there are so many things that can go wrong.
Mine is available and it's on ebay right now. I will send you a link in PM so not to break forum rules.
Everything I've done to it is documented by receipts plus all of the thing PO's have done as well.

 

6-11-22 update:

Ran the engine to operating temp one final time (since the car will be down for a while during conversion) and checked bunch of parameters. She runs great with no codes!
Then I proceeeded to remove SMG for 2nd and final time!
Got careless and stripped one of upper torx bolts and Craftsman bolt extractor to the rescue.
Before I put in the 6 speed tranny, I will prep the area by cutting the insulation where the shifter assembly comes through, remove the SMG wiring harness and maybe some other stuff that is easier to do in empty cavity.
On the side note and I hope I'm not breaking the rules, my SMG is for sale here and I'm very motivated seller and will give much better deal to anyone here if they pay directly through paypal:

E60 E61 E63 E64 BMW M5 M6 SMG Transmission with Complete Valve Body | eBay

Removed from my 2006 BMW M5 with 139k miles but it will fit any E60 E61 M5 or E63 E64 M6. SMG pump electric motor @ 122k miles. Disasembled SMG pump and replaced all of the internal o rings and seals.

www.ebay.com

Also, my custom tranny jack adapter is also for sale (last picture) and will give good deal to forum member.

 

Another update:
Even with lift, M5 kicked my old *** but I've acomplished a lot this weekend:
New crank seal, E90 M3 Luk flywheel and clutch are in.
Tranny is pretty much ready to be bolted in, all components inside bell housing refreshed.
Redid the plugs where gear oil pump use to reside. I Initially made half *** design cover which leaked. This time I slowly tapped all 4 holes and plugged them properly.
I've also finished the pedal assembly which was trully PITA! I initally wanted to find used assembly and just swap everything but could not find it. So I bought all individual clutch pedal components. If I had to do it again, I'f probably do it in one hour instead of 4. But, I was missing one part and the other wouldn't fit etc...
I've read where people had issue installing the long curved clutch fluid metal line between master and slave cylinder but I had no issues thanks to previous experience. The trick is simple: Install it from under the car while tranny is out.
You still have to wiggle and turn it but it's so much easier than doing it from inside.
Few pictures:

 

You are missing a grommet on the clutch line that goes through the body. There is 2. One on the line and another that goes over the the other one from the tunnel side the seals it. It’s impossible to install it later.

 

You're right, I remember that now from when I did my E39 as it has similar double groomet design. No big deal, I will seal it with some proper black silicone or something and make it look decent. It's out of sight so I will make sure it's functional rather than good looking.

 

Mind if I ask where you got an M3 tranny for $1300?

I've been stewing on the swap idea for a while and it seems I may have waited too long. Seems it's really taking off and becoming a popular thing. Now I can't find a reasonably priced trans, or really reasonably priced parts in general lol

 

Not at all, prussian motors on ebay. I've noticed the same so I snatched it. I've also used Schmiedmann for few parts as their prices were better on some parts, even after shipping. Still, some parts are simply NLA (used or new), so you will have to get creative as I did with shift selector rod.

 

Let me also ad that prussian motors were great! This was "damaged tranny" with cosmetic damaged as something grenaded inside and chewed up the walls little bit but JB weld fixed it fine and permanently. Still, I found some more damage that wasn't pictured and they gave me additinal discount as asked.
On the other hand, I had some douchebag buy my SMG and then screamed murder even though I've described the issue in listing.
I just refunded him and told him to go to hell.
The point is, here you have legitimate business trying to make an honest $ and on other spectrum, true piece of individual crap.
Ranting over, lol.

 

I'll be starting my swap soon as well and something just occurred to me. My car has a heated steering wheel. A genuine manual steering wheel is already a unicorn, much less a heated one? Does anyone know if there even is such a thing?

 

It does exist. At least there is a part number for it. Finding it might be tricky.

32342283937

 

The heating element in the steering wheels is glued In between the leather. It makes it impossible to separate as it breakers the heating element upon removal. You can recover it by adding another layer of leather on top of it. It will result in very thick wheel and also takes a while before it heated due to the extra thickness.

I have done a couple. Some people like it most don't. I tend to stay away from them.

If anyone is interested in more detail send me pm. I don't want to derail the thread.

 

did you have to switch any body harness? Reading other forums, there is talk about a 6-speed body harness to make it work? I did not see a conclusion to this install inthe thread.

 

There is a big thread on this forum going into details about wiring. I went with option of purchasing new 6 speed manual wiring harness which is plug and play on tranny side but not on ECU side.
I've sold the car with never completing ECU side but everything worked fine other than some warning lights on dash.
Actually, the new owner (we stayed in touch) just completed everything recently and there are no warning lights of any kind.

 

Thanks for the reply. I did see some posts that you did complete it, just was pretty good detail here up until it stopped. Thanks again.

 

No problem. Between the big thread on Manual Conversion and E39 Source excellent 3 part video, there is wealth of information avaliable.
I'm actually getting closer to start on my M6 Manual Conversion. I have all parts sitting on shelf (a lot of parts!) but don't want to start it until SMG goes kaput.

 

Oh - one other note - for all programming, I bought a cheap windows laptop ($200 or so) and then bought a laptop drive off FB marketplace which was sold with all of the BMW software already installed (I think $100 including shipping - might have been less).

Buying it all pre-installed on a laptop drive was AWESOME! Easiest way to get everything you need without doing all the setup on a laptop.

 

Thank you for posting this valuable information.
Me and you saved this beauty from the brink of doom and I'm so happy to hear you put over 4k miles since you bought it.
You should probably copy / paste your post to this thread:

https://www.m5board.com/threads/our-future-swap-smg-for-6-speed-manual.165033/#replies