I finally finished the overhaul on the 4L80E.
Had the converter rebuilt and stall raised.
Finished the cooling system plumbing (still need the efans).
Finished the fuel system plumbing (still need to upgrade the pump).
Finished 90% of the wiring (still need to wire the EZ-TCU).
Bought a 2017 Mustang GT catback ($50, yay Craigslist) to mate up with the axle forward section of the 2010 Camaro SS catback ($25, yay Craigslist).
Starting the exhaust down pipes now so I can fire up the engine in-car before winter puts the brakes on the project until things warm back up.
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Pic overflow to post #27
S.F.
Last edited by StolenFox; 07-02-2017 at 09:40 AM.
Overflow pic from post #27.
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Last edited by StolenFox; 07-02-2017 at 09:42 AM.
Today I built the converter down pipes using the 2010 Camaro SS parts, mandrel bends and new stainless flanges.
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Last edited by StolenFox; 07-02-2017 at 09:47 AM.
Wonderful feeling hear it come alive, I'm sure. Slick work on the exhaust too!
The exhaust looks awesome!
Sweeeeeeeeeet! I like the intake, flip it upside down and cut a hole in the hood.
Slowly reworking the harness to add all the emissions hardware back in and switch from DBW to DBC. Also switched from the truck PCM to 04 GTO
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Amazingly the 04 GTO evap canister vent solenoid is a perfect fit for the E39 Charcoal canister. Just had to make a bracket that mimics the E39 leakage detection pump mounting setup.
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Also started fabricating the buikhead fitting I need to mount the GM fuel tank pressure sensor in the E39 fuel level sender / pump mount flange.
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Mounted the B&M transmission cooler where the E39 Aux cooling fan used to reside.
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And chopped up the ghetto eBay Silverado cold air kit to get it in the car. It's crap, no quality at all so it is definitely temporary.
Pic overflow to Post #38
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Last edited by StolenFox; 07-02-2017 at 09:57 AM.
Sooo, test drive this weekend?
Overflow Pic from post #36
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I wish, here's the list:
install evap vent
install tank pressure sensor
figure out how the fuel level signal to the PCM (dual Sender on passenger side maybe) and install it.
install electric fan
switch 4L80e cooler fittings, run AN hose from trans to cooler
install Lokar 4L80E dipstick
fill trans with ATF
install EZ-TCU
pull 6-cyl diff and axles
reinforce diff mount
install 540i diff and axles
measure driveline and have modified
install drivveline
cutout and raise the spare tire well.
finish the exhaust
buy and install Lokar shifter
do the 100 things I probably forgot about.
Pray everything jives.
Maiden voyage.
S.F.
Last edited by StolenFox; 07-02-2017 at 09:58 AM.
I'm having flashbacks... that stuff took me months to complete. I thought you were a little closer for some reason. Either way, stay at it!
Big day for the project: successfully fired the engine with the harness reworked to drive by cable, new, 04 GTO PCM, emissions hardware added and the EZ-TCU mocked up. Doesn't sound like much but with all the wiring changes it's a big deal. Oh and the transmission seemed to be ok, no leaks or weird noises when I lit it up. Gotta a rear O2 error so I need to check my wiring but it was a good day!
S.F.
Last edited by StolenFox; 10-29-2016 at 09:41 PM.
Congrats! The thats a huge victory.
Great job! It takes quite a bit of thought and ingenuity to work through all of the issues/roadblocks. Subscribed!
Well, I still stink at Tig welding aluminum! Reinforcing the diff mount was a real bear but I got it done. Was unable to reach the left side of the front of the mount, even with the short tungsten cap I couldn't get the torch in there. So it's going to have to stay as is.
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Last edited by StolenFox; 07-02-2017 at 10:02 AM.
Any reason you didn't just pull the subframe out? It's easy, especially with all that crap out of the way.
Well, that would have been easier except she's a long way off the ground:
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And I don't have stands tall enough to reach the rocker pads. Most likely this is all temporary since M5 diff's and axles are priced like gold I'll probably buy another subframe and mod it for a Ford 8.8 from an IRS Explorer. Custom axles will be expensive but at least the sky's the limit when it comes to gear and Posi options.
SF.
Last edited by StolenFox; 07-02-2017 at 10:03 AM.
After reinforcing the diff mount I've installed the axles and the differential. Also, borrowed a tech 2 scanner and performed the crank angle variation learn to clear the check engine light. Pulled the shifter assembly and ordered some stuff from Shiftworks to hopefully build a cable operated shifter using a factory BMW unit from a early E39. I also bought a universal aluminum fan shroud and modified a Taurus 2-speed efan to fit:
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Overflow pic post #47
Still have to paint, install & wire but this is a good start.
S.F.
Last edited by StolenFox; 07-02-2017 at 10:10 AM.
Overflow pic from post #26
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Taurus two speed fan with a Volvo Fan relay controlled by the LS PCM ground trigger.
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Last edited by StolenFox; 07-02-2017 at 10:13 AM.
So since it's 20 degrees in my garage I decided to bring a spare pump module to the kitchen table for modification. For my emissions legal swap I had to incorporate the fuel tank pressure and level senders from the 04 GTO to my E39 pump module:
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See post #50 for overflow pics.
To do so, I built a bulkhead fitting for the pressure sensor and made mounting bracketry for the GTO fuel sender. To get the GM sender signal out of the tank I added two additional BMW pins to the BMW module in the unused slots in the middle of the Electrical connector. Just drilled the unused spots, pressed in the pins and connected to the GTO sender. I'll add the corresponding female pins to the car's pump wiring connector to complete the circuit to the GM pcm.
S.F.
- - - Updated - - -
Oh yeah, I also installed the Fuel Lab 340lph pump to the basket...
S.F.
Last edited by StolenFox; 07-02-2017 at 10:27 AM.
I welded the V-bands to the cat pipes and intermediate H-pipe. Used some bends to reduce the pipe centerline so I could get past the fuel tank:
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Installed the intermediate pipe hangers and modified the factory plate to help support them:
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And then mounted it back up:
See post #50 for overflow pics.
Mocked up the 2016 Mustang GT catback to see how it would work, fits amazingly well:
See post #50 for overflow pics.
Lastly, check out the awesome factory GM booger weld on the intermediate pipe:
See post #50 for overflow pics.
S.F.
Last edited by StolenFox; 07-02-2017 at 10:34 AM.
Overflow pics from posts #48 and #49:
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Sorry, don't know how to edit videos and they suck. Too excited to care!
S.F.
Last edited by StolenFox; 07-02-2017 at 10:39 AM.
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