1999 740iL Manual Transmission Conversion

[Playdoctors]

Hello. New member here with a new project.

I've read a whole lot of posts about this swap and it seems like it should be relatively straight forward.

I have sourced many of the parts I need and am looking for some advice and information.

The parts I have sitting in my shop right now are:

(all from a 2000 540i)
6 speed manual trans
pedal assembly
shifter and linkage
clutch hydraulic hoses

The parts I plan to buy new are:

Clutch kit
Master and slave clutch cylinders
Clutch release bearing
Rear main engine seal


As for questions:

Does anyone know how much the driveline needs to be extended by? I don't want to have the driveline lengthened, I would rather have a spacer machined. I'm an engineer so I can get the part modelled in CAD and milled out of billet.

What parts am I neglecting?

What can I do about the shifter in the center console? Do I need to buy a European console trim and boot?

Thanks in advance for any help - I plan on spending the next few months gathering parts and information and then carrying out the swap when I have everything lined up.

[Binjammin]

I'm not sure, but I don't think anyone has easily cracked what you need to code the facelift e38s to, to avoid issues. You may want to look into that further before you start throwing parts into your car.

[blackknight530i]

Hey, I'm doing this along with my S62 swap right now and I can give you a few pointers. Also, check out my build log in my sig for things I ran into.

First, you will need clutch lines ordered from BMW in Germany as they are specific to the 7. They are the same for the euro 728i and 740i manual models, though the 740i manual wasn't made beyond 8/97 or so. You will also need to transfer the clutch and brake pedals from the 540i pedal assembly to the 740i assembly due to the fact that the 540i assembly doesn't have the parking brake on it. Instead they have a hand brake. The clutch master cylinder needs to be for the pre-facelift 540i due to design changes on the newer 540i. Your biggest problem will be finding the shifter arm and selector rod as both parts are no longer made by BMW, so find yourself a good welder and get the 540i parts extended by exactly 15mm and keep them straight. With the driveshaft, you have a couple options, and neither includes making a spacer. One is to send your driveshaft to a shop to have the front section re-tubed (replace the front tube with a longer tube and weld it to the joints) and balanced. The other is to get a new driveshaft made by Portland Driveshaft which is pretty local to you in Portland, OR. In either case, the front section needs to be lengthened 88mm. The shop that lengthened mine is Carolina Driveline in Spartanburg, SC and they charged $159 plus shipping both ways and it looks like it came from the factory that way. I think the re-manufactured one from Portland Driveshaft is closer to the $400 mark, but it comes with all new joints and is rebuildable. You will also need to wire up the reverse wire to the cluster. You will also need to figure out what you need to do for the DME software on a M62TU car. You can probably use the 540i manual software flashed using winkfp, but since I'm using a MSS52 from an M5, I don't have details on this.

Here are a couple links to help you out:

http://forums.bimmerforums.com/forum...d-Factoids-FAQ
http://forums.bimmerforums.com/forum...swap-the-parts

Parts List PDF:
http://bimmerboard.com/members/cody3..._Part_List.pdf

The parts I used that are a bit different are an e60 545i shifter with ZHP shift knob. You do not need a different console nor the wood trim, just the shift boot and the foam insulation under the wood trim. Those are definitely still available from BMW. If you want a more complete parts list, I can get one put together for you with part numbers and prices that I paid just a couple months ago. Even with the parts you have, expect to spend about $1000 or so in other parts. Also, get yourself a set of E-torx sockets or at least E10, E12 and E14, because if you try to use standard sockets on the transmission bolts, you are pretty much guaranteed to strip them. You will also need a long T60 torx bit in order to remove the flywheel to get to the rear main seal. I also didn't see a flywheel in your current price list, but you may have been including that in your clutch kit.

Hopefully I've covered most of the things you need.

- - - Updated - - -

I'm not sure, but I don't think anyone has easily cracked what you need to code the facelift e38s to, to avoid issues. You may want to look into that further before you start throwing parts into your car.

I don't see why he couldn't flash just the DME with the 540i flash since they are essentially the same car. I could see there being a difference with automatics if they had different shift points or something, but since the engine effectively works the same and talks to the same modules, I don't see why it wouldn't work, especially since he has a pre-2001 740il. They added a few emissions devices in late 2000 for the 2001 model year that might have given a problem, but I doubt it would be a problem for his.

- - - Updated - - -

Also, for coding, it might be easier to use PA Soft, rather than the method CDH posted in his FAQ I posted. I'm pretty sure you can change option codes and such much easier in it.

[007008]

I have fixed mine to run as a true manual, no check engine light.
http://forums.bimmerforums.com/forum...ap-well-almost

[Binjammin]

I have fixed mine to run as a true manual, no check engine light.
http://forums.bimmerforums.com/forum...ap-well-almost

So you're still running clear? Awesome!

[007008]

So you're still running clear? Awesome!

Yep, all is fine. I will do a more detailed step by step soon. Once I confirm it works on another car.

[Binjammin]

hotness

[anmasher]

I will be going through this shortly so this thread is very helpful already. I'll chime in if I come up with anything else pertinent and useful as the project moves along.

That's great that the 540i shifter assembly can be lengthened!

[M I C H A E L]

Yep, all is fine. I will do a more detailed step by step soon. Once I confirm it works on another car.

You're awesome! Lol

[Playdoctors]

Wow. Thank you guys - the info in this thread is awesome. Turns out I was pretty uninformed on the electrical side of the project. I also have some learnin' to do on system names and acronym/initialism meanings.

[Liquidity]

The clutch master cylinder needs to be for the pre-facelift 540i due to design changes on the newer 540i.

735i master cylinder works just fine.

[007008]

735i master cylinder works just fine.

True, but to buy one in the US you have to use the 540 because websites do not list the euro 7 series.

[maddoggyusa]

Thanks BlackKnight.

I ordered a bunch of parts for the swap in early Dec, and the selector arm is one part that still hasn't come in. Somebody else on here had a new one... so I figured it would still be available??? I was able to get the 740 euro crossmember. I need to send my driveshaft out to your Carolina shop... I may contact them this week.

[Moughrawn]

Have you seen this post?

http://forums.bimmerforums.com/forum...hlight=6-speed

[007008]

Thanks BlackKnight.

I ordered a bunch of parts for the swap in early Dec, and the selector arm is one part that still hasn't come in. Somebody else on here had a new one... so I figured it would still be available??? I was able to get the 740 euro crossmember. I need to send my driveshaft out to your Carolina shop... I may contact them this week.

I think think the selector rod is NLA. The trans crossmember is also used in the Z8.(useless trivia)
When I first stopped in at Carolina Driveline he said it shouldn't be a problem. I think they have done 5 since then.

[blackknight530i]

Carolina driveline did mine and I just installed it today. It was the perfect length and honestly, I couldn't really tell that it was custom. The welds look like factory and I'm impressed, especially for how little I paid. Also, I told them what I was doing (6-speed swap) and that I needed it extended 88mm, and they said no problem. No other questions asked, so it sounded like they knew exactly what was needed.

The selector rod is confirmed by BMW to be NLA. I've thought about contacting UUC and seeing if they would make a shifter arm and selector rod like they do for the e39, but extended 15mm to fit the e38. It might be a great upgrade, and it would keep people wanting to do this swap from having to get parts custom made.

[Liquidity]

As long as you give them the parts and the dimensions it doesn't matter what length it needs to be or what it's used for. It's just a pipe welded to some u-joints. Any drivetrain specialist can do this. I see people paying exorbitant amounts of money for this but it shouldn't cost you more than $150 if you supply the flanges, yokes and u-joints. Lots of these shops rely on the ignorance of the genpop. Call FleetPride next time.

[007008]

UUC made one of the shifters for Craig (CDH), I know he still has the specs for it.

[Binjammin]

If anyone has a welder and a little free time, fabbing up a selecter rod is very easy. You can use any bmw manual transmission selecter rod, cut it, and splice in a section of tubing to length. Tack the tubing in place, shift forward and back to test, if it works thsn weld it up. Very easy job.

[CharlesAFerg]

Yep, all is fine. I will do a more detailed step by step soon. Once I confirm it works on another car.

Can't wait to hear about this. This will be my next project.

[gigjoec]

subscribed

[DUDMD]

For those that want the DME reprogrammed to manual version, I can help with that.

Sent from my iPhone using BF.com

[Playdoctors]

I hate to say this but I'm backing out of this project.

I've been looking for a Jaaaaaaaaaaaaag for a couple of years and finally found one - a 2000 XJR.

So the 740iL is up for sale, as is the 6 speed transmission andthe pedal set etc. Hit me up if you want any of those parts.

[Cobrajet429]

I'm can't see where you are located, I might be interested in what you have for the manual swap if you are close enough and the price is right.

[M I C H A E L]

I'm can't see where you are located, I might be interested in what you have for the manual swap if you are close enough and the price is right.

seattle, wa.