540i 6 speed swap thread

[Jcbe34]

Most have seen my other post, but for those who haven't.. I recently bought a '94 Hellrot/tan 540iA, and we all know hellrot 540i's can't be automatics, so I am swapping the 6 speed parts off my '95 540i/6 donor car.

120k 540iA


Big ticket item.. took me awhile to find this


Kind of intimidating.. this was suprisingly easy though. (I used Mr. Projects post for reference.)


This is the bolt that holds the pedal box to the steering column bracket. Huge pain in the ass! Taking it to work tomorrow for removal with an air chisel.



I've made this post for reference, as well as help from all of you out there that have done this. I know I am going to run into some problems here and there.

Also started modding, don't really know what kind of drop Im going to get with these. But Im planning on getting shorter front spring pads, konis and e32/e34 touring sway bars

[E34N]

Very nice... I'll definitely be checking in...

[HE53]

Very nice... I'll definitely be checking in...

ditto

[kalevera]

The sheer bolt's actually pretty easy to get out. Easier with an air chisel, but also easy with a hand chisel and a hammer. Tap to cut it, then rotate through the cut.

[Mr Project]

Or just cut a slot on top so you can remove it with a screwdriver. I think I was able to get a cutoff wheel in there.

[Jcbe34]

I might end up doing that, but I was very unprepared today and have no cut-off wheels. I think that would be safer than the air chisel. I was very close to deciding to weld the clutch return spring tab onthe auto pedal box.. but this is so much easier.

[Mr Project]

Yep, I was thinking the same thing and you're absolutely right. The way you're doing it is the right way....far easier and less risky.

[Mohamed 525i]

watching

[liquidtiger720]

nice

[brosher]

Looks like fun!

[Goat128]

Also started modding, don't really know what kind of drop Im going to get with these.

Almost to the ground. They're made for 6cyl.

[DannyH4]

keep us updated on this project!

[Jcbe34]

Yeah thats what I figured with the springs, but I'll work with it, as long as its as low as I want in the front I'll be ok.

Got the pedal boxes swapped today, again, not difficult at all. Cutting a groove in the sheer bolt on the column is definitely the way to go. I'm about to put the pedals and steering column back in the car tonight.

[larse34530i]

do you still have the 4l engine from your donor?

[Jcbe34]

Yeah its still in the car, alusil motor as well

[Jcbe34]

Didn't get to work on it too long tongiht, but I got the pedal box/column back in. It was a little frustrating, but not difficult. I started the pedal box nuts finger tight first, then threaded the 2 upper pedal box bolts before tightening the lower nuts. The pedal install is pretty straightforward, but it can also be a little tedious. I ran a bolt through the opposite side of the brake pedal to line everything up so I could insert the pedal bolt.

Here you can see how close the two pedal boxes are, notice the clutch return spring bracket on the bottom right of the left bracket.


I have 3 pedals! still waiting on my clutch cylinder and I have to pull the lines off the other car still. hopefully I will get this done before the weekend when I go on vacation


This is the shift-interlock cable. Definitely do not remove this one, or your key will stay in the ignition. You have to tie down end of the interlock cable, this was a little annoying, but I got it after a little bit of garage engineering.

[larse34530i]

I am interested in your 4.0. How much do you want and can we set it up soon.

[larse34530i]

Yeah its still in the car, alusil motor as well

do you have a price set I would like to purchase this from you ASAP.

[Jcbe34]

uhh... I would take $900 for it, but this car is a roller. Interior is stripped, no driveshaft, no transmission, auto pedals. All wiring is unmolested though

[larse34530i]

uhh... I would take $900 for it, but this car is a roller. Interior is stripped, no driveshaft, no transmission, auto pedals. All wiring is unmolested though

That would work for me do you want to give me a call or give me your number so I can call you and get this worked out as far as shipping and payment? DO you have the ecu/DME

[txp135]

It's nice to see ppl giving e34 TLC. I'm considering the Vogtland springs with konis sports also. Did you find any info about another 540i with this combo? Thanks.

[Jcbe34]

That would work for me do you want to give me a call or give me your number so I can call you and get this worked out as far as shipping and payment? DO you have the ecu/DME

Its going to be a couple weeks. I still need it around for a couple things. But yes, it will be complete with the ecu... nothing has been removed except most of the 6 speed stuff.

It's nice to see ppl giving e34 TLC. I'm considering the Vogtland springs with konis sports also. Did you find any info about another 540i with this combo? Thanks.

Not really, I'm thinking its going to be really low in the front though. I'll have to wait and see.

[chris345i]

I just had a thought. I want my cruise to work properly when I do mine. Jonathan, have you looked into how to wire in the clutch switch? I'm sure I can figure it out but I just wanted to mention that in case cruise control matters to you.

[Jcbe34]

I've thought about it. I believe I read there is a way to do it, I'll see if I can't dig it up. Cruise control is pretty low on my list of priorities though. You started your project yet?

[larse34530i]

[quote=Jcbe34;9081256]Its going to be a couple weeks. I still need it around for a couple things. But yes, it will be complete with the ecu... nothing has been removed except most of the 6 speed stuff.



Ok that is fine I guess I was hoping for sooner than later but let me know.
Dave