So it begins... US 840Ci 6 speed swap

[olinjohnston]

Hey forum,

Even though we have a few threads on the subject already, I wanted to create one that chronicles my adventures in putting a Getrag S6S 420G manual transmission into my 1994 M60 840Ci. Now, please keep in mind that this is a LONG TERM project, so updates might be a little scarce. That said, I have already begun to gather the parts necessary to complete the swap:




For this project, the shift knob, E31-specific linkage parts, and hardware will be new from BMW, but in an effort to make this swap as economical as possible:

The transmission will be sourced used (likely from an E34 or E39 540i)

The clutch will be purchased new online.

Clutch/brake pedals, pedal bracket, and clutch hydraulics will be taken out of a junked manual-transmission E34 5-Series.

The drive shaft will be sourced overseas or custom-made

and the differential has already been swapped out with a 3.15 limited-slip unit from an early E32 750iL.



***A full parts list will be added once everything is acquired.

[toomanyparts]

Cool and finally!

[cer54467]

sounds good, also has any one put a 4.4 m62 into a Hole where a m60 was? What sensors need to be changed? Modified?

[olinjohnston]

sounds good, also has any one put a 4.4 m62 into a Hole where a m60 was? What sensors need to be changed? Modified?

Yes, you just keep it OBDI, and use the 4.4L block. Seen two done so far in person. I don't see what this has to do with the 6-speed though.

[lawlshane]

Looking forward to this Olin. Anything different needed to do the swap on an M62 car?

[olinjohnston]

Looking forward to this Olin. Anything different needed to do the swap on an M62 car?

The only difference I'm guessing would be the electronic procedures needed to get the car to start without the automatic. Also, you might need to use a transmission from the later E39 540i and not the earlier one to accommodate the crankshaft position sensor, which is at the flywheel of the M62 instead of the front on the the M60.

[garylafortuna]

A project you've been contemplating for a while Olin. Are you planning to go with BMW parts right across the board, or have you thought about using some after market stuff, like shifter, clutch, etc? A worthy enterprise sir. Will this make you stand alone as a 6 speed 840 owner in North America?

[olinjohnston]

Are you planning to go with BMW parts right across the board, or have you thought about using some after market stuff, like shifter, clutch, etc?

No aftermarket stuff. I want it to be as if BMW built it from the factory.

Will this make you stand alone as a 6 speed 840 owner in North America?

No, I know of at least four, personally seen two, and have driven one.

[DenverMDM]

Not to be a jerk, but wouldn't it be easier and cheaper to source a V12 6speed?

[olinjohnston]

Not to be a jerk, but wouldn't it be easier and cheaper to source a V12 6speed?

No because they are rare, not cheap, and would likely not already be as sorted out as the one I've owned for 6+ years...Then I'd be stuck trying to sell this one in a relatively soft used car market. Aside from that, it wouldn't be a V8 6-speed, which is the whole point of this endeavor. Also keep in mind that a used transmission for this car goes for $600-1000 depending where you find it (not an expensive rarity like the V12) the pedals and stuff will be pennies on the dollar at a pick-your-part junkyard, and I get employee pricing on all the new parts, which is cost+ pricing, not a % discount, so some things are like 80% off.

[X5X]

Not to be a jerk, but wouldn't it be easier and cheaper to source a V12 6speed?

That you just make it a wannabe CSI :P

- - - Updated - - -

Keep us posted! I am still considering doing an S62 conversion + 6 speed

[TedBobo]

Hey forum,

Even though we have a few threads on the subject already, I wanted to create one that chronicles my adventures in putting a Getrag S6S 420G manual transmission into my 1994 M60 840Ci.

Humm...moved to Coto de Caza (or somewhere close), new 4 series, now this. Lotto winner or recent cartel inductee? Guess "silver" won't be present at the next couple of WrenchFests.Looking forward to the outcome. There's an 840 that was at one of the earlier WF's that had the conversion...all I recall is that it was navy or dark blue.

[olinjohnston]

Humm...moved to Coto de Caza (or somewhere close), new 4 series, now this. Lotto winner or recent cartel inductee?

Hardly...I'm actually not spending that much on this project. And I've seen cell phone bills that are higher than what they charge me for that 4-Series.

There's an 840 that was at one of the earlier WF's that had the conversion...all I recall is that it was navy or dark blue.

Yeah, it's also a 94. Avus Blue with the 4.4L block swap too. It belongs to John Burgan:

http://socaleights.com/wp-content/up...ember_2012.pdf

[TJC1]

Great project and I'll be following it as so far one of the things that has held me back from getting an E31 is the lack of manual transmission cars available here...yes I know they are available with the V12, but they are somewhat few and far between and sometimes command a premium that makes this project make sense. Are you going to be changing out the gauge cluster as well, or is it really necessary?

[tvjake2]

Olin - will this project start soon? Will you make the Mullen trip with us?

[M I C H A E L]

Cool to see you finally moving along with this... btw that e31 you linked is stunning. ESP those wheels!!

[TedBobo]

Thx Olin, that means there's 2 conversions. The other 840 was definitely a darker hue and definitely not John's 8er.

[olinjohnston]

Are you going to be changing out the gauge cluster as well, or is it really necessary?

Not necessary. The manuals have the exact same instruments, but without the EGS inputs from the automatic transmission, the gear indicator LCD is blank.

Olin - will this project start soon? Will you make the Mullen trip with us?

As soon as possible. I need to locate a LOT more parts, and I might not be doing the work at my house. I will complete this, but it's a long term project. This thread might be quiet for several months. Don't worry.

I work every weekend, so unfortunately I miss a lot of the get-togethers. Definitely won't miss Bimmerfest though.

Thx Olin, that means there's 2 conversions. The other 840 was definitely a darker hue and definitely not John's 8er.

And there are others! Ron Inchausti (the mechanic in charge of John's did a Diamond Black one for himself) and a previous forum member, "Nukeduster" I believe did one too.

[8eights]

He did, Nuke sold that car though.

[IcemanBHE]

Yeah, it's also a 94. Avus Blue with the 4.4L block swap too. It belongs to John Burgan:

http://socaleights.com/wp-content/up...ember_2012.pdf

Spent 5 hours in that car. John is a cool dude.

[Terminator77]

This is a fun project!!! Will keep watching..

It's gone feel like you are driving a whole different car afterwards.. a better one!!

[Wuffer]

Avee up here in BC converted his 840. Also supercharged it...

[Bluesman]

Will be following this closely Olin, Great project

[olinjohnston]

UPDATE 4/20/14:

Picked up the meat of the swap this morning... The S6S420G:




The condition looked a little rough, so I am concerned. I think it has been sitting in the garage a LONG time. I don't have any experience with these units, so if anyone can offer some advice on how to judge its condition, that would be much appreciated. The input shaft is rusty, etc, but I got the transmission down to $300 (sorry V12ers), so it was worth the risk to me.

[B10 BITURBO]

Ok,, as i am not well in the US 840 history,, but as far as i understand,, there are 3 examples of 840 6g in the states,, are they oem G420,, or converted cars ??