[CHARIOT]

Day 1 was a moderate success!

My goal with this project is to gradually do as much of the legwork ahead of time that I can, this way the downtime is minimal. After all, this is my DD so i need it for the daily work commute.


Pedal assembly is here along with the hydraulic pipes for the clutch hydraulics:

It was cheaper to buy both pedals as an assembly than just the clutch pedal, SO, I decided to take a different route here. Removing and installing the pedal assembly is tricky due to the steering column motor being in the way so I decided to simply unmount the clutch parts from my used pedal on the bench, and reinstall them into my already installed pedal assembly in the footwell.

Another thing to note is that the SMG footwell shroud is not cut out for the clutch pedal. (Easy to fix with a dremel)

Foam is there

Pedal is in, and hydraulic hose is run through the firewall up to the brake fluid reservoir.

More to come

 

[CHARIOT]

When pinning the clutch switch and running wires there is already a blue/black wire in the CAS in position 41. This wire is going to the SMG, so since the SMG ecu will be removed, you can repurpose this wire for pin 2 on your clutch switch. The other end of the wire can be removed from the SMG connector and relocated to position 18 on the DME where it needs to go.

No need to run additional wires into the engine bay if not necessary.

 

[theraj]

good luck man, this is great

 

[CHARIOT]

good luck man, this is great

Thank you, thank you!

Shifter parts will be here tomorrow.

Actual cost so far:

Pedal assembly: $61.39
Shifter assy: $42.16
4 Hydraulic pipes: $153.05
Transmission: $1,380.20
New Clutch Kit: $400.38
New Flywheel: $449.78

 

[Fiftytwoeighty]

Thank you, thank you!

Shifter parts will be here tomorrow.

Actual cost so far:

Pedal assembly: $61.39
Shifter assy: $42.16
4 Hydraulic pipes: $153.05
Transmission: $1,380.20
New Clutch Kit: $400.38
New Flywheel: $449.78

Love it!

 

[Esteban Grullon]

Even though I don't think I will ever get rid of the SMG on mine. Good work sir!

 

[CHARIOT]

Shift linkage arrived, albeit missing the b!tch clips and carrier bushing, but that's no big deal.

aaaaand a last minute deal on a transmission after the previous one fell through after discovering some undisclosed damage:

http://www.ebay.com/itm/302022252286?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT


Mine

 

[Craze]

What was wrong with other tranny?

Wonder if anyone in australia has done this? Haha

 

[CHARIOT]

What was wrong with other tranny?

Wonder if anyone in australia has done this? Haha

There's nothing wrong with the current SMG, in fact I drive the car every day.

When I got into the market for an e60 M5 I swore to myself that I wouldn't settle for an SMG (I've driven sticks all my life). The problem is that 6MT M5s are literally like 1 in 20, and when one comes up for sale it's gone before you know it. Sure enough, I settled and ended up with an SMG, and this is just my way of getting what I originally wanted.

Oh, and the flywheel came today:

 

[ucsbwsr]

I approve of this message. Save the manuals!

Evan

 

[CHARIOT]

The biggest mystery of this whole thing has been the transmission harness; for some reason only the transmission side can be ordered from the dealer. The top half of the harness that goes to the engine bay has a part number but cannot be ordered seperately because it is part for the engine bay harness assembly.

If you do this retrofit, just find a complete transmission harness used when you find someone with a used manual M5. It may not be an easy find (mine wasn't) but it's better than building the harness yourself.

This one set me back $40

Here's the X6021 connector and its female connector counterpart whose wires will go to the DME and light module. When looking this up in ISTA you should be aware that the connector is pictured wrong on BMW's behalf in the diagrams/connector view. The diagram shows an 8 cavity connector with 8 large square slots, but the connector actually has 12 cavities. 4 big, and 8 small.

And here's the x60681 connector which joins the trans side harness and engine bay side harness.

 

[CHARIOT]

Some members asked for some details/close-ups of the terminals and connector, so without further ado:

Connector (Supplier is Kostal):

And the male pin terminals for the connector on the HARNESS SIDE (supplier is AMP/Tyco): BMW PN 12527512135

These are the terminals we need for the connector on the ENGINE BAY SIDE of the harness. BMW PN 12527510671

#1 pictured above is not the right one. We need the one which doesn't have the wider back for the rubber weather-pack insulator bushing.

All available form your local dealer parts department or other preferred BMW parts vendor

 

[CHARIOT]

The BMW schematics for the x6021 are wrong when compared to the actual harness. The x6021 connector is shown as an 8 pin connector, but is actually a 12 pin connector when you get the harness. Because of this, none of the pinnings on the drawing for the trans harness sensors match the actual connector. I have manually veified each of the circuits with my multimeter, and illustrated everything below:

ACTUAL wire colors and cavity orientations coming from the original harness as arrived.

 

[ucsbwsr]

Respect for taking the time to create all this info (I can relate). But be prepared for people to still be lazy and ask for a spoon-fed step-by-step DIY guide. I kindly tell those people that if you need a step by step DIY guide then maybe a transmission swap isn't in the cards for them.

Evan

 

[Hamster]

Respect!
Thanks for sharing and making this precise and comprehensive DIY.
I do miss sometimes a good old MT.

Good luck and looking forward for successful swap.

 

[CHARIOT]

New clutch kit has arrived:

I must admit, I was expecting it to be bigger. Not to mention I wasn't aware the manual used a dual friction disc setup similar to the SMG.

Notice it also came with the updated style release bearing....very happy about that

Updated total inventment so far:

Pedal assembly: $61.39
Shifter assy: $42.16
4 Hydraulic pipes: $153.05
Transmission (Found a different transmission than originally planned): $944.00
New Clutch Kit: $400.38
New Flywheel: $449.78
EDC Buttom w/trim: $40.00
Misc. Dealer small parts/odds&ends. (Will itemize later once complete.) $37.19

=$2128.66

The only remaining part that is required to keep the car driveable is the drive shaft. The seller is local, so I'm waiting for the transmission to show up so that I can evaluate the condition of the other attached trans. parts so that I can order replacments if necessary. Once that is done, it's a trip down the road to get the drive shaft and everything goes in.

At this point, i'm shooting for next weekend for the install.

 

[CHARIOT]

I decided to take on some more of the prep work while I wait for the transmission....I figured I'd look at the DME connectors and check all the cavities for the wires we need to run, and to my confusion, some of these cavities were already populated. For starters, the X60005 connector pin #9 (where we need to add in the wire from cavity 7 in our connector above for the manual trans temp. sensor.) already had a blue wire there. This totally caught me off guard because the SMG temp sensor goes to the SMG, not DME.

What the...?

Blue wire already there:

Followed the wire, and it goes to this little blue 8 pin connector:

The male pin is there - it's the top row, second one from the left.

However, its female counterpart is not in the other side of the connector:

This means we don't have to run our wire to the DME, we can run it to this cavity instead, we'll just need one of the bigger female terminals, like this:

The x60002 connector also has 2 cavities already occupied - 19 and 6. These need to be spliced into. The schematics show these going to a splice to serve as power/ground for some other sensors on the engine.

Same applies to the x60001 when moving the yaw rate sensor from the SMG ecu to DME. Pins 10 and 11 are already populated, so SPLICE into these. 9 still gets added as originally planned

 

[Hasan Shaikh]

This is awesome :cheers:

 

[CHARIOT]

details for the misc. small items like clips, pins, etc.

 

[Craze]

Has anyone else done manual
Conversion??