This thread is intended to be a list of parts, steps, inside tricks, etc that need to be performed during the 6 speed conversion. This is not intended to be a mechanical guide including how to remove and install the parts, but it should provide you with everything you need to know before tackling the conversion.
I recently finished the conversion, and have it fully functional as stock, including no TRANS FAILSAFE error, working cruise control, 'S' display in the instrument cluster, and proper throttle control with the manual. Hopefully this will dispel the myth that a manual EML computer is required for the conversion. For clarification, I am currently using the automatic DMEs and EML computer.
Eventually, I will compile the information shared here into a proper DIY thread, but this is meant to be an open discussion before that point.
First, the parts list. In addition to this list, you will also need a clutch pedal assembly from an e31, e32 or e34, a clutch master cylinder (PN: 21-52-1-155-425), the soft clutch line to the reservoir (PN: 21521163714), and two firewall grommets (PNs: 21-52-1-156-082 and 21-52-1-159-206). The parts list does not include the exhaust mounts that bolt to the transmission (PNs: 18-30-1-723-518, 18-31-1-716-874, and 18-31-1-716-878, 2 each) or the 6-speed specific undertray splash guard (PN: 51-71-8-118-725).
Parts List
Description Part # Quantity List Price
Shifter Parts
Shifting Arm Upper 25-11-1-221-576 1 $40.72
Bearing, Shifter arm 25-11-1-221-581 1 $27.60
Bolt, Shifter Arm 07-11-9-915-047 2 $0.38
Selector Rod, lower 25-11-1-221-577 1 $56.68
Shift Rod Joint 25-11-7-503-525 1 $37.51
Securing Clip 25-11-7-571-899 2 $0.66
Plastic Washer 25-11-1-220-439 4 $0.25
Bitch clip, Left 25-11-1-221-579 1 $11.80
Bitch clip, Right 25-11-1-221-580 1 $11.80
Shifter bush (round) 25-11-1-221-578 2 $7.65
Shifter bush (oval) 25-11-7-519-670 2 $2.89 (My shift carrier took these, not the above. I ordered both for cheap insurance)
Plastic shift cup 25-11-1-220-600 1 $10.33
Rubber inner shift boot 25-11-1-220-785 1 $16.18
Shift Lever 25-11-7-527-253 1 $69.02 (Z3 2.8L/3.0L)
Short Shift Lever 25-11-7-527-254 1 $69.98 (MZ3, 25% reduction in throw, replaces above. recommended)
Gearbox Mounting/Suspension
Cross Member 23-70-1-137-868 1 $45.88
Tranny mount 23-70-1-137-870 1 $161.44
Tranny mount flange 23-70-1-137-869 1 $89.64
Bolt w/ washer 22-32-6-760-945 4 $1.10
Flat washer 07-11-9-931-096 2 $2.56
Hex nut 07-11-9-922-857 2 $0.73
Hex bolt w/ washer 07-11-9-915-093 2 $0.51
Torx Bolt 23-00-1-222-888 8 $1.58
Flat washer 07-11-9-931-698 8 $0.40
Torx Bolt 23-00-1-222-887 2 $1.15
Flat washer 07-11-9-931-660 2 $0.40
Hex Nut 07-11-9-922-857 2 $0.73
Wave washer 07-11-9-932-112 2 $0.09
Dowel 23-11-1-606-156 2 $9.53
Driveline
Driveshaft 26-11-1-226-673 1 $919.37
Center Guide Bush 26-11-1-226-696 1 $11.35
Guibo (110mm/14) 26-11-1-227-419 0 $128.27
CSi Guibo (110mm/14) 26-11-2-227-577 1 $136.73 (I used this with CSi driveshaft, replaces above)
Hex Bolt 26-11-1-227-829 6 $3.62
Guibo Nut 26-11-1-227-830 6 $1.38
Clutch
Clutch Kit 21-21-1-223-413 1 $876.50
Flywheel 11-22-1-736-395 1 $669.54
Flywheel Bolts 11-22-1-717-841 9 $2.43
Pilot Bearing 11-21-1-720-310 1 $23.65
Slave Cyl 21-52-1-161-874 1 $185.16
Slave pipe @ slave 21-52-1-159-392 1 $12.25
Slave pipe long 21-52-1-159-565 1 $65.79
Nuts for slave 07-12-9-906-196 4 $1.64
Studs for slave 21-51-1-203-012 2 $4.03
Pivot pin 21-51-1-223-281 1 $24.60
Fork Lever 21-51-1-204-229 1 $14.08
Fork retaining clip 21-51-7-570-284 1 $4.77
Pressure plate bolt 07-11-9-919-939 6 $0.38
Total before tax
$3666.96
Electrical
The electrical involvement is required in only three places of the car:
Starter
In order to get the starter to fire, two terminals must be jumped across the starter relay. This is exactly how the factory performed this operation. The photo below depicts the jumper (red wire) that replaces the removed relay directly above it.
Trans Fail Safe Program warning elimination
In order to keep the car from giving a TRANS FAILSAFE PROG error every time you start it up, you must ground pin 9 of connector X506 [located behind and to the right of the HVAC display panel, it is a white 12 pin plug]. (Picture to come)
Cruise Control and Throttle Control
In order to have functional cruise control and proper EML throttle adaptation, you must ground pins 4 and 5 of connector X18055 [located behind and to the right of the HVAC display panel, it is a
black 12 pin plug]. Additionally, this can be performed at the DMEs (pins 63 and 64), or the EGS transmission computer (pins 24 and 25). (Picture to come)
Location of X506:
Picture of X506 before making jumper harness (the red wire in the photo is the power wire for my V1 radar detector:
and finally, a somewhat organized series of photos during my conversion, taken straight from the old 6-speed swap thread:
Here's what a factory fresh Getrag S6S 560G looks like
I had some spare time this afternoon, so I pulled out the automagic and replaced it with a real man's transmission..
Excuse the white powder all over the trim pieces, I had just taken off a pair of nitrile powdered gloves. Unfortunately I also forgot to take a picture of the UUC cerametallic clutch going in :/
If you were wondering what the difference between auto and CSi driveshafts is, here you go:
The CSi (possibly all manuals?) uses a larger CV joint at the diff than the automatic and is the same length. I ended up using the rear portion of my stock driveshaft and the front portion of the CSi mated together.
boxes full of many parts
here you can see where I performed surgery on my mufflers to do the 'Dinan exhaust mod'
The underside of the car with the exhaust removed
The shift console coming apart
The transmission as installed
The complete shifter assembly installed
Close up on the shift selector
Another close up of the shift selector with the output shaft
The back of the tranny with the modified driveshaft and CSi flexdisc installed
The center support carrier, to the left of the carrier is the CSi portion of the driveshaft, and to the right is the 850iA portion
And a shot of the flange at the diff. My CV boot is torn, so it looks like that driveshaft rebuild will be needed very soon
Please comment and add to my list if you have any information (Randy ), I'll do my best to recall any more small details in the meantime.
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