My e39 LSx swap

[M5Hunter]

Been a while since I made any updates. Been real busy with work. Haven't done a whole lot to the car in the last month. I did go to a local BMW dyno day a couple weeks ago. I threw in a couple gals of 110 to mix in with the 93 in the tank and cranked the boost up a little bit. Each person was allowed 3 pulls, 2 of mine were no good due to spinning on the dyno. They hosed down the tires with some traction aid and we made one more pull. Here was the outcome:



860lb/ft was made at 24.5psi. Sadly I didnt get an accurate HP number due to my ignorance. I turned up the boost controller but failed to raise up the "overboost protection", so when it went over 24.5psi the controller dropped it back to 18psi. Oops.

Last weekend I was looking over the car and noticed the intake pipe/turbo inlet was loose. The 90* elbow that went on the turbo inlet had come loose(ripped off) and actually got sucked into the turbo, which chewed it up some. No damage was done to the turbo, but the charge pipes and I/C was full of pieces of rubber. What a fun time I had cleaning that out.



I used a much nicer, thick silicone elbow this time.

The last part of my update is a cosmetic thing I did. I hated the way the front M5 bumper looked without the foglights installed, but with my 4" I/C piping there was no way to fit the lights in there. Saturday I decided to take the fogs I had and cut the backs off of them. I left only the lens and the mounting tabs. Then I spray painted the inside of the lens black. I think it turned out pretty good! I also made a "air duct" in one of them to try to feed the filter cool/fresh air.

[nsogiba]

Looks good. close call on that turbo chewing up parts!

[unnatrl]

The modified fog lights look good. I've been contemplating the same thing. It's crazy how fast you run out of room behind the bumper! Now, let's see some track times at 24psi!!

[1NAWTY5]

859.99 Wheel Torques.....NICE! I like the way the fog lights are in as it helps complete the front cosmetics.

Now you have to update the wheel torque thread again why not go for 900

[Lanaue]

Ok i know it was a long time ago but what was done to get the M5 rear in a 528?

[M5Hunter]

Ok i know it was a long time ago but what was done to get the M5 rear in a 528?

The diff is a direct bolt in. You will need m5 axles and and a m5/540 driveshaft to modify

[M5Hunter]

I may have mentioned before that my transmissions been giving me some issues the last couple months. The biggest part of the problem is it sounds like someone dumped a box of rocks in it. Secondary issues were difficulty getting it in 2nd and 3rd gears under heavy load. Pulled the trans out and found an issue with the shifter that was keeping it from going all the way in 2nd gear. One problem down! Popped the case open and started examining.
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Pulled the input shaft away from the main shaft and found the noise culprit. A cone bearing on the input shaft had started eating itself up and was allowing the main and input shaft to touch, which makes a bunch of noise when they are turning different speeds.
Tough to see in the pic, but the bearing is missing some material on one side and it's actually turning purple from heat.
image.jpg
Ive been reading that this is a common issue due to lack of lubrication on the bearing. During hard acceleration, all the oil goes to the rear of the case, away from this bearing and the front gears. Which leads to the 3rd gear issue. Lack of lube and jamming 3rd gear at 6800rpm doesn't go together well. The engagement teeth and synchronizer on 3rd gear were rough. They are getting replaced.
Heres a random pic of everything apart on my bench.
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I pulled everything completely down and sent out all the shafts and gears to be polished and cryro treated. I'll be replacing the 1-2 and 3-4 synchronizers, all bearings, all blockers, all seals and upgrading the shift fork pads.

Lastly I'm going to add two spray nozzles inside the trans case to shoot fluid directly on the input shaft bearings and on the 2nd and 3rd gears. The nozzles will be fed by an external electric pump that will be powered when my methanol injection system comes on.

As parts roll in, I'll add pics.

[RVAE34]

Excellent work, Clay. Very interested to see your sprayer setup!

[auaq]

Were you not thinking of upgrading to something better at one point? Remind me but what transmission is this?

[rao]

Looks good. Not too late to buy mine, it already has the sprayer installed

[M5Hunter]

Were you not thinking of upgrading to something better at one point? Remind me but what transmission is this?

It was a bone stock T56. I was considering sending it off for a full build by Tick Performance but decided against it. I'm gonna do a few little things to it and stick it back together.

Looks good. Not too late to buy mine, it already has the sprayer installed

Yea, I just saw that post yesterday. I wish I had seen it before ordering parts and sending stuff out to the cryo place.

[B10 BITURBO]

These ouput numbers are really impressive

[M5Hunter]

Here's a little look at some really pretty parts that I hope to not see again for a while.

[auaq]

I say sell it to an art museum as some decorative art.

[Skunkedtsi]

Awesome numbers and the car looks fantastic to boot, hats off to you sir!

I have a very similar build almost complete and I am worried about keeping the engine cool as well as melting parts close to the collectors. Has the drivers side collector caused any issues being that close to the Heater Valve controller? I was contemplating having the collectors ceramic coated or at least wrapped. Looking at your set-up, and obviously how good it runs gives me hope, is that just a high temp paint you have sprayed them with? I don't want to cover up all the pretty stainless if I can avoid it, but in the same breath I don't want to have a car I' am always worrying about overheating or melting things either.

[M5Hunter]

It's been a while but I'm finally getting around to puting my transmission back together



More pics to come this weekend when I can get some more done

[RVAE34]

Excellent!

[M5Hunter]

Messed with the trans some today.

Untouched trans housing


Hole drilled and 1/4" npt to -6 AN fitting installed


-6 AN 90* hose end


Here you can see fitting placement in the case. I'm going to trim it down some and make some kind of nozzle on the end to point fluid.


To feed the pump the drain plug is replaced with a 1/2" npt to -8 AN fitting


Waiting on the fluid pump and some fittings to come in on Tuesday. Hopefully some more updates soon after.

[douglee25]

Has anyone done something like this before? Do you plan on running it through a small HX'er? Looks pretty slick.

[M5Hunter]

There are a few guys here and there that have done it. I've been considering putting a cooler on it but I've gotten advice to see what the operating temps are before I do that. It's something that I can easily add any time.

[M5Hunter]

Got some parts in today. I'll make a complete parts list with item numbers when I have it all done.

Here is the Tilton fluid pump



Tilton recommended this Earls pre filter. It's more of a screen than a filter




For the nozzle I decided to just modify the npt fitting. I cut it down the center, crushed the end in the vice and cut it again to get everything straight. It's not real pretty but it works well



Here is a quick video of the nozzle and pump test. Should lubricate everything well

[douglee25]

I dig it.

[auaq]

I approve.

[mapleridge]

skills.

[sanpt7777]

Having done both swaps, E36 and E39, which did you found to be harder?

I want to build an LS (5.3 truck engine) powered BMW, but there are many ways to do it.

Since I'm on a budget, I will most likely buy a car that broke down, or one that works but is not exactly mint. I've read many threads and apparently 540i is a harder swap due to steering and subframe. But then again, a 540i will come standard with more features and luxury than a six cylinder. Or just get a mint 6 cylinder?

Now, the E36 is another story. While it seems easier to do because it's older and swap kits are cheaper, it may be harder due to engine bay space?

Sorry for hijacking your thread, but I'd like to know your opinion.

EDIT: By the way, I'm staying NA. Don't think I have the skills yet but probably can also get the mounts made by my uncle's shop (he builds membrane structures).