Is the 525 to wimpy for a stick shift conversion?

[av8r4aa]

Still loving the “Chuck Wagon” looks good, drives very nice. The coldest AC of ANY car
I have owned. It will actually make your face hurt if you let it blow on max cold.
The auto tranny is working great, I’m just bored with 2 pedals.
My question is the 2.5 engine just to slow to have a good time with a stick shift conversion?
It’s a mid year 2003 nice example with 150K. No leaks, great body and interior.
I plan on keep it for 5 more years, or so.

And for those that have done this , 5 or 6 speed transmission?

[BimmrMeUpSnotty]

The 525 actually feels more alive with the five speed. The slush ox does just that, make it slushy. Stick with a five speed, and research what final gear you need to get. With the autos final gear at the diff, you will be running an extra thousand rpm while cruising at 65.

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Never thought about running a six speed using the stock auto final gear.

[Toby B]

+1

the 5 speed and a 3.23 or 3.15 diff is just fine. You have to keep revs up, but that's the fun part.

and the 6 speed ought to be just about right for the auto diff ratio, right?

t
would put a 3l in while he was at it, but also thinks that an M54B30 is the answer to everything.

[TexasTouring]

Not at all, the 525i/5 is a great drive! Nice and happy to rev up and with the right diff ratio it jumps off the line.

[effduration]

+1 on man swapping the 525i…I just posted this on bimmerfest.

I daily drive an '03 530i sedan that I manual swapped 4 yrs ago. It runs great.
The process to swap a 525i is identical to the 530i and it's the same sedan and wagon..
mechanical, wiring (not much), Coding (not too bad) . Swapping a 540i is slightly different.

The easiest trans for your 525i will be the 5-speed ZF S5D 320Z which was used in the 525i manual wagon and 530i sedan.
But, you can also easily install the 5-speed Getrag S5D 250G( used in 525i sedan) in your 525it if you get the driveshaft that goes with it. ... Either one will work

A 6-speed can be done, but it’s more work, and maybe 2x the cost.

Here is what I would grab from a manual parts car for your swap :
-Transmission
-flywheel and clutch components
-driveshaft
-rear differential (don't use the one from an auto)
-shifter assembly, boot and trim (top & bottom)
-Transmission elect connector with a foot or more of slack
-pedal box (clutch and brake)
-clutch and brake switches on pedals (if any)
-clutch master cylinder and it's switch
-clutch slave cylinder
-clutch line - rubber /steel
-hose from brake reservoir to master cylinder
-Big rubber grommet covering auto shifter hole in transmission tunnel (remove insulation from below)

#1 Pro-tip.. Be sure to wire in the cruise control switch. If you don't you might have a rev hang...

Here are a couple of links- search any add'l link referenced in these links

Manual Swap 2003 525iT
(particularly post #31)

2003 530i Auto to Manual Swap

[KeysCoupe]

I’ve got all the parts to do an M54B30/37BZ 6 speed from an E46 330zhp into my ‘01 525ti. I’ve got to modify the driveshaft and fab a trans crossmember. Other than that, it mostly bolt-in. I’ll be using a tall diff from a 5 speed car.
-Donny

[KeysCoupe]

I came across a 2000 5 speed 525i in a U-Pull yard today. Too bad it won’t be on the road again, but good parts to pick for a manual swap.
-Donny

[BimmrMeUpSnotty]

I came across a 2000 5 speed 525i in a U-Pull yard today. Too bad it won’t be on the road again, but good parts to pick for a manual swap.
-Donny

You mean a 528, or a 540.

[KeysCoupe]

You mean a 528, or a 540.

No badges on the trunklid, and I didn’t look at the label in the door jamb, so I am probably mistaken. I went by the inventory tag on the quarter panel showing as a ‘00 525. Definitely a 6 cyl car, so probably a 528 as you say. What trans is that? ZF 320? I may go back and grab the 5 speed.
There was also a ‘99 540 with a 6 speed. A 420G?
-Donny

[BimmrMeUpSnotty]

Yep, if it’s a 2000 528, it will be the ZF320Z

[KeysCoupe]

You mean a 528, or a 540.

I got back to the car with the 5 speed manual. It is a 525. The date on manufacture is 9/00, making it an ‘01 model year. The vin is WBADT33411GF40023 that confirms it came with a 5 speed.
-Donny

[effduration]

I got back to the car with the 5 speed manual. It is a 525. The date on manufacture is 9/00, making it an ‘01 model year. The vin is WBADT33411GF40023 that confirms it came with a 5 speed.
-Donny

That means it will have a 5-speed Getrag S5D 250G, unless it is a touring.