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  #101  
Old 05-15-2017, 02:57 PM
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williamx5 is on a distinguished road
Good day all!!

Well, I was going to pull my driveshaft today and have it extended by a local driveline specialist in my area. He quoted me the same price for extending my E53 original or shortening a longer version (if I was able to find one)... $159 with no shipping since I'm local... That is about the price of something used, IF I was able to find the section I needed at the correct length...

HOWEVER!! I discovered this today when I went to re-verify the extension I need for the OEM E53 drive shaft... The E53 guibo does not mate up to the E39 540i manual trans output flange... SOOOO, I need to get a 540i front section and cross all my fingers and toes that it will mate up to the back section of the E53 drive shaft...

This is a little hard to see with the flash, but the centering pin isn't in the center...



And the bolts obviously don't match up...



I guess the other alternative would be to find the output flange off the E53 3.0L manual and cross fingers and such that it matches the splines of the 540i 6...

Going to mess with the cross member tonight if work doesn't get in the way again!!

Cheers for now...
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2001 E39 540i Sport 6 speed (10-12-2000 build date) Anthricite exterior / Tan interior
***2000 540i/6 PARTS CAR!!***
2001 E53 X5 4.4i (03-07-2001 build date) White exterior / hellbeige interior (6MT swap vehicle)
2002 E53 X5 4.6is (12-20-2001 build date) Imola Red exterior / M-texture interior
2004 E53 X5 4.4i (11-18-2003 build date) White exterior / Black interior
2006 E53 X5 4.4i (08-30-2005 build date) Silver exterior / Gray interior
BMWCCA member (#4745)
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  #102  
Old 05-15-2017, 09:21 PM
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Good day all!

Well, I got my clutch parts... I think I will try to get them installed and finalized these coming days off... I would have never guessed the clutch arm pivot pin is plastic... But, I guess it works well enough to last over 200K miles... So, don't fix what's not broken... Here are the parts I got!





I ordered three pilot bearings since the BMW version was 22 bucks... These were off ebay for $7.50ish, $8.50ish, and over $12.00 for the Timken... I think the Nachi is the original made in Japan... Timken bearing is made in China... The Fag bearing is made in Korea... I honestly think the OEM Nachi is the best bet here... We'll see!! I will end up using all these pilot bearings, so I figured I would see how well one would hold up compared to the others...









I also did some much needed research after discovering the Universal Joint, as BMW calls it, or Guibo as we call it, is a different size for the 540i and X5... I am only able to use the driveshafts from a diesel version E46, the E34, the E38, the E39, and E31... So, to filter down this list a little... There are no diesel E46's in the US, the E34 has the center U-joint on the trans side of the center bearing (no-go), the E31 is too rare... That leaves the E38 and the E39 line-ups... Since we are pulling most everything else from the donor 540i, may as well keep the drive shaft for modification at a driveline shop...

The only unknown at this point is if the union at the two halves is the same for both vehicles... If not, I will need to give the driveline shop both drive shafts and have them use the trans end of the 540i shaft to extend the trans end of the X5 shaft... That might be very do-able since they have to use material to make it longer anyway... May as well use OEM BMW tubing... IF the two are the same diameter!! Again, another hurdle to cross...

Going to see about a guy with a welder for this cross member... Maybe I can get one of these hurdles completed tonight...

Cheers for now!!!
__________________
2001 E39 540i Sport 6 speed (10-12-2000 build date) Anthricite exterior / Tan interior
***2000 540i/6 PARTS CAR!!***
2001 E53 X5 4.4i (03-07-2001 build date) White exterior / hellbeige interior (6MT swap vehicle)
2002 E53 X5 4.6is (12-20-2001 build date) Imola Red exterior / M-texture interior
2004 E53 X5 4.4i (11-18-2003 build date) White exterior / Black interior
2006 E53 X5 4.4i (08-30-2005 build date) Silver exterior / Gray interior
BMWCCA member (#4745)

Last edited by williamx5; 05-15-2017 at 09:39 PM. Reason: Pictures!!!
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  #103  
Old 05-16-2017, 02:40 AM
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Good day all!!

Here are the before pictures...







During clean-up... Stage 1...









And fine tuning the bracket removal...













Donít forget to pull this prior to bracket removal... Then put it back!!





Painting will be done as soon as I get home... A final cleaning and paint to keep the rust away!!





So, I was talking to my welder buddy with some ideas... The tube for the bolt is in the way of the original idea... So, I was thinking about going right down the center with the cut (center of the trans)... Then just putting one plate in there... Essentially, filling the void where the cut was made... Then just put a single plate at the bottom of the one coming from the cross member, to kind of make an odd ďTĒ...

Iíll take this back to the vehicle tomorrow morning and take some measurements... And some pictures!! I hope we can get this welded up tomorrow night and test fitted for my two days off...

Iím working as quickly as I can on this guys and gals!! I might be over cautious, but I need the first one to be nearly perfect so I know it will work! And maybe have room to be even better, if someone sees something I donít!!!

Cheers for now!!
__________________
2001 E39 540i Sport 6 speed (10-12-2000 build date) Anthricite exterior / Tan interior
***2000 540i/6 PARTS CAR!!***
2001 E53 X5 4.4i (03-07-2001 build date) White exterior / hellbeige interior (6MT swap vehicle)
2002 E53 X5 4.6is (12-20-2001 build date) Imola Red exterior / M-texture interior
2004 E53 X5 4.4i (11-18-2003 build date) White exterior / Black interior
2006 E53 X5 4.4i (08-30-2005 build date) Silver exterior / Gray interior
BMWCCA member (#4745)
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  #104  
Old 05-16-2017, 12:52 PM
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Very Cool!
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Current garage:
'03 4.6is
'93 Jeep Cherokee (XJ)
'07 Jeep Liberty (KJ)
'08 Civic Si

Former garage:
'08 Mercedes C350
'08 Chevy HHR SS
'95 Mitsubishi Eclipse GSX
'90 Chevy K5 (Full on monster truck)
'89 BMW 325ic E30
'75 GMC Jimmy (Full restoration)
'76 Jeep CJ7 (Full restoration)
'74 GMC Jimmy (trail rig)
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  #105  
Old 05-18-2017, 09:04 PM
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Good day all!!

Well, I got the front half of the drive shaft I need to experiment with... So the thought process was to swap the front half of the E39 540i parts car with the back half of the E53, and have it modified to the correct length... Well, as my luck would have it, the bearing and the splines are NOT the same...

Here are the splines... E53 are smaller... about an inch here...



And the E39 (I have an E38 740i here, but they are the same)... Almost 1-3/8 here...



The bearing is obviously different, as is the mounting distance for the bolt holes... This is center to center...





HOWEVER!!!

The tubes are the same size... This is a rough measurement, but even if they are a millimeter different (not sure why BMW would do that), the drive line shop should be able to make it work...





I have to measure again and again and again and again to make sure I get this right... I know this is a work in-progress and it needs fine tuning as time and the project goes on, but this one I want to get perfect, down to the millimeter the first time!!











I think I will also bolt the front half to the manual trans in the X and get a verification measurement... As it stands right now, before the multiple measurements and verification measurement, I will use 456mm of the E53 shaft and 466mm of the E39/E38 shaft... It is 922mm from the trans side of the E39 guibo (bigger than the E53) to the end of the U-joint side of the bearing...

I initially had attempted to get a shaft that was the correct length and just bolt it in... I should have considered the difference in vehicles weíre dealing with... One is mostly performance and the other is mainly a super fun AWD minivan... Okay, maybe not that bad... I just canít get the two to have a common crossover area with the drive shaft... We have to splice to get it to work... BUT!! At least BMW used the same tubing for both drive shafts...

Iím open to ideas!! So, instead of having the driveline shop use their tubing to lengthen the shaft, Iíll just have them cut and weld all OEM BMW tubing...

Cheers for now... Iím still getting the other stuff measured and together... I think I will have to weld the aluminum shifter arms together... Maybe Iíll just have a bunch welded up and avail for those that need them... Or, I guess you could always have a welding shop do it... My apologies everyone... I canít figure a reasonable solid way to keep it from failing... Iíll get pictures of that asap...

Cheers for now everyone...
__________________
2001 E39 540i Sport 6 speed (10-12-2000 build date) Anthricite exterior / Tan interior
***2000 540i/6 PARTS CAR!!***
2001 E53 X5 4.4i (03-07-2001 build date) White exterior / hellbeige interior (6MT swap vehicle)
2002 E53 X5 4.6is (12-20-2001 build date) Imola Red exterior / M-texture interior
2004 E53 X5 4.4i (11-18-2003 build date) White exterior / Black interior
2006 E53 X5 4.4i (08-30-2005 build date) Silver exterior / Gray interior
BMWCCA member (#4745)
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  #106  
Old 05-18-2017, 09:15 PM
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squidzilla is on a distinguished road
My hell William none of this scares you? You are the man. I am glad I did not try this on my own. Thanks for being the pioneer.
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2001 E53 X5 3.0 Auto. Silver Black Build date 10-17-2000 140k miles
2001 E46 330xi Auto. Silver/Black Build Date 11-30-2000 135k miles
2004 E60 545i Sport 6MT. Black/Black Build Date 6-2004 83k miles
2003 E53 X5 3.0 5MT Silver/Black Build date 11-25-2002 90k miles
2003 E53 X5 4.6is Black/Black Build Date 8-2003 109k miles
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  #107  
Old 05-18-2017, 09:24 PM
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Quote:
Originally Posted by squidzilla View Post
My hell William none of this scares you? You are the man. I am glad I did not try this on my own. Thanks for being the pioneer.
Hey!! Naaaa... Actually, on the contrary!! I actually think this is fun!! It is the end result that really makes it all worth it... Firing up that motor and letting out the clutch for the first time...... Oh, my!!

I actually did this to a 95 T-bird, but not to completion... The Military called me overseas and I had to sell the project... No room to store it for that long...

I mean to see this one through!!

Cheers!!
__________________
2001 E39 540i Sport 6 speed (10-12-2000 build date) Anthricite exterior / Tan interior
***2000 540i/6 PARTS CAR!!***
2001 E53 X5 4.4i (03-07-2001 build date) White exterior / hellbeige interior (6MT swap vehicle)
2002 E53 X5 4.6is (12-20-2001 build date) Imola Red exterior / M-texture interior
2004 E53 X5 4.4i (11-18-2003 build date) White exterior / Black interior
2006 E53 X5 4.4i (08-30-2005 build date) Silver exterior / Gray interior
BMWCCA member (#4745)

Last edited by williamx5; 05-19-2017 at 07:58 AM.
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  #108  
Old 05-18-2017, 11:27 PM
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I would just take both shafts to a drive shaft shop and get a new one made based on new lengths and connections.
__________________
Current garage:
'03 4.6is
'93 Jeep Cherokee (XJ)
'07 Jeep Liberty (KJ)
'08 Civic Si

Former garage:
'08 Mercedes C350
'08 Chevy HHR SS
'95 Mitsubishi Eclipse GSX
'90 Chevy K5 (Full on monster truck)
'89 BMW 325ic E30
'75 GMC Jimmy (Full restoration)
'76 Jeep CJ7 (Full restoration)
'74 GMC Jimmy (trail rig)
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  #109  
Old 05-19-2017, 10:43 AM
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Quote:
Originally Posted by smokeyyank View Post
I would just take both shafts to a drive shaft shop and get a new one made based on new lengths and connections.
Absolutely!! So, that is what I did this morning after installing both halves in the X... I marked where they would mate up and pulled them from the X... I lined up the marks and measured 919mm from the end of the X splines to the mounting ear of the guibo... I pulled the guibo and the center support bearing so they wouldn't be in the way at the driveline shop... I took the shafts to Carolina Driveline of Spartanburg... I ask if I could use their name... Obviously, they didn't mind...

I was curious how they were going to do the extension and where they would put the weld... He stated that the ends I need to keep would get cut, cleaned, and prepped for new tubing... So, no welding of the OEM tubing like I had figured... I think that might be a good thing too... He stated the new tubing would be thicker and in pristine condition, so less chances of having a weak spot from this or that over the years... I'm excited to see the finished product!!!

Ahhh, now I am off to install the clutch components... I may even hook up the hydraulics and test that out...

Cheers for now!!!
__________________
2001 E39 540i Sport 6 speed (10-12-2000 build date) Anthricite exterior / Tan interior
***2000 540i/6 PARTS CAR!!***
2001 E53 X5 4.4i (03-07-2001 build date) White exterior / hellbeige interior (6MT swap vehicle)
2002 E53 X5 4.6is (12-20-2001 build date) Imola Red exterior / M-texture interior
2004 E53 X5 4.4i (11-18-2003 build date) White exterior / Black interior
2006 E53 X5 4.4i (08-30-2005 build date) Silver exterior / Gray interior
BMWCCA member (#4745)

Last edited by williamx5; 05-19-2017 at 12:11 PM.
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  #110  
Old 05-19-2017, 03:13 PM
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Nice! I was going to say I know from having many shafts done for my jeeps most times they just get new tube and attach to u-joints to them and presto bongo! I'm glad you're making head way, I get all giddy every time I log in and see this thread at the top!
__________________
Current garage:
'03 4.6is
'93 Jeep Cherokee (XJ)
'07 Jeep Liberty (KJ)
'08 Civic Si

Former garage:
'08 Mercedes C350
'08 Chevy HHR SS
'95 Mitsubishi Eclipse GSX
'90 Chevy K5 (Full on monster truck)
'89 BMW 325ic E30
'75 GMC Jimmy (Full restoration)
'76 Jeep CJ7 (Full restoration)
'74 GMC Jimmy (trail rig)

Last edited by smokeyyank; 05-19-2017 at 03:22 PM.
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