2001 E53 4.4L 6MT swap?

[bcredliner]

It's fun to break new ground. I applaud those that take the risk.

Based on your first post your goal is to get away from the stock automatic transmission you are having problems with and perhaps improve economy.

Going to 2wd will gain some HP/TQ lost in AWD hopefully resulting in better economy. And, a manual transmission driveline fully locks where the torque convertor always allows some slip. Also, to best of my knowledge it would be one of a kind if that is important.

Even though you already have a manual 6 speed, there are so many unknowns in a conversion and still considerable cost and time investment, I would have the transmission rebuilt, add Dinan transmission software and be done with it. I am at about 117,000 miles on original transmission in 4.6 that is heavily modded. I have the Dinan transmission software and have changed the fluid with ZF fluid every 40,000 miles. I recently replaced the internal wiring harness--that's it. The Dinan software will give you more attributes of a manual transmission and you can add more fun if you do a paddleshift steering wheel conversion.

If you want to improve economy I would first try tires that were at least an inch taller to see what happens to economy and if you like how it is on the highway. If that gives you what you want then find diffs that get that same highway rpm with stock tires. The reason to try tires first is the change might not improve economy if the engine is not running as efficiently as much of the time. Rather than seeking a particular highway rpm I would try to get as close to the rpms where the engine is most efficient at the speed I normally travel.

FYI, due to frontal area and weight, the maximum speed of a stock 4.6 is 153 mph. Wind resistance is then a wall.

[williamx5]

Originally Posted by bcredliner

It's fun to break new ground. I applaud those that take the risk.

Based on your first post your goal is to get away from the stock automatic transmission you are having problems with and perhaps improve economy.

Going to 2wd will gain some HP/TQ lost in AWD hopefully resulting in better economy. And, a manual transmission driveline fully locks where the torque convertor always allows some slip. Also, to best of my knowledge it would be one of a kind if that is important.

Even though you already have a manual 6 speed, there are so many unknowns in a conversion and still considerable cost and time investment, I would have the transmission rebuilt, add Dinan transmission software and be done with it. I am at about 117,000 miles on original transmission in 4.6 that is heavily modded. I have the Dinan transmission software and have changed the fluid with ZF fluid every 40,000 miles. I recently replaced the internal wiring harness--that's it. The Dinan software will give you more attributes of a manual transmission and you can add more fun if you do a paddleshift steering wheel conversion.

If you want to improve economy I would first try tires that were at least an inch taller to see what happens to economy and if you like how it is on the highway. If that gives you what you want then find diffs that get that same highway rpm with stock tires. The reason to try tires first is the change might not improve economy if the engine is not running as efficiently as much of the time. Rather than seeking a particular highway rpm I would try to get as close to the rpms where the engine is most efficient at the speed I normally travel.

FYI, due to frontal area and weight, the maximum speed of a stock 4.6 is 153 mph. Wind resistance is then a wall.

Good day!!

All I really want to do is be able to pop-start the X if the battery is low.......

Okay, not really... Being rare is a bonus, but I'm really after the fun factor of my E39 540i/6 squashed into the roomier and bigger SAV equivalent... I love my 540i6, but I've gotten use to sitting up a little higher...

Going 170 MPH really isn't my goal, unlike what I kinda said earlier... It is just a by-product of what I really want; lower RPM's at a given highway speed... I have gone 155 MPH's when I was stationed in Germany for that short year... It is completely worth it if you have the means... To be "allowed" to cruise at or near the electronic limit of the vehicle is truly worth the price of admission!!! BUT, I wouldn't want to do that in the X5... It's just got such a big butt... It would be difficult to really control in any sort of cross wind...

I think initially I wanted to get rid of my problematic 6hp26 in the 2004... But that is going to be down the road as the parts to convert it have not yet hit the "cheap" area that the E39 540i parts have... I thought about purchasing another 2001-2003 so I don't mess with my 2002 4.6is since it still works great... I can't seem to get it back from my better half... That is a little frustrating, but a totally different topic of conversation... Oddly, I purchased the 4.6is with the impression from the seller it had a bad transmission... It ended up being the "aftermarket splined" front drive shaft... The DS failed but didn't even mess with the TC splines... I didn't think it was possible either until I looked at the TC... The TC in the X had better splines than the one I purchased to replace it... So, it became my daily driver... I was going to pull the TC and weld the planetary gears to have a locked RWD until I got my replacement TC... That didn't happen, but for the better...

Okay, book is long enough... Sill waiting on the 2006 to get resolved... It just sits out there and looks at me with a evil sort of smirk... It agrees, I think, that it was a little warmer so things could progress with it's repairs...

Cheers!!!

[williamx5]

GOOD DAY ALL!!!

WhOOOOO HOOOOO!!!!! Guess what I got in the mail today!?!?! YEP!!! The clutch tubing parts came in today!! I was worried that it wasn't pre-bent... IT IS!!! I'm so excited I don't have to worry about dealing with that portion!!! I have to order about ten... Just so I will have them avail...

So, I was looking back and noticed that I didn't have some items noted... This is the Clutch Delay Valve (CDV)... It slows the rate at which the clutch is engaged for inexperienced drivers... It annoys those of us that know how to use the clutch...



I removed this one... See the smaller diameter insides?





Here is the pedal area I cut away using the tape template I made from the stock E39 brake pedal... I cut away all the yellow and tada!!



From right to left, we have the stock E39, the modified version I won't use (pre 2001 brake pedal), and the good one with the cover...



This is the pre 2001 pedal... Bearings and different design... I don't like it!!





Here are the new parts... I am so crazy excited this is pre-bent! Really!! You have NOOOO idea!!!



and I got ten of these... ECS made me buy ten... They fill the hole where the brake fluid supply comes in from the master cylinder reservoir... There is just a plastic plug in that hole now...



I got ten of these too... Think ECS made me buy ten of these too... Clutch stop buffer... Non-clutch units don't have them... Duh, right? Guess you could fashion anything to go there... BUT...



and my unit all ready to go... I might start getting the updated input clutch cylinder... It has a slot for the start-disable and cruise-lockout in one hall-effect switch... Maybe... if the parts are cheaper, I'll go that route... I'm pretty sure the newer version (not pictured) is way more plentiful in the salvage yards...



Oh, I got fluid hose... Could just save it from the E39 you pull the pedal assembly from... Or have new... 6 in one; half dozen in the other...



Okay, that is all I have for now...

Cheers!!!

[williamx5]

Good day all!!

Well, I figured it was time for an update... I am just about done with "6" and I will be getting "1" Monday afternoon if all goes as planned... My new patient is a non-sport 2001 (hence "1") 4.4L with transmission issues... I was going to use 2 as the first to get the 6MT transplant, but it is just doing so great right now... I'd hate to take a good operating X5 down when there are others out there that need rescue...

As it stands right now, I have two complete sets for the PF version X5's... I'm still trying to source a good supplier of N62 version 6MT's and accessories (Flywheel, pressure plate, yada yada)... The 545i manuals aren't just as plentiful as the 540i/6's are... Which should be a crime in my book!!

I have not recieved the shifter arm or associated hardware from ECS yet... So, I guess I don't quiet have two complete sets yet, technically... Drive shaft and trans cross member are going to be a project after the trans is installed...

I'm going to have transmissions and front differentials avail for cheap if anyone needs one or knows someone that does... I guess that also goes for T-cases and front driveshafts...

Okay!! So, I'm super excited to get this under way... Three more days... Just three more days if things go as planned...

Cheers for now!!

[BimmerM3inGA]

Awesome! Can't wait to see the "real" work begin!!

[smokeyyank]

Awesome! Can't wait to see how this shakes out. Hoping it works and I can start sourcing parts and do this next year.

[williamx5]

Good day all!

Figured it was time for an update... I finally got the project vehicle in the CLEAN garage and prepped for surgery! I failed to get any pictures prior to getting it put in the garage. I drove the vehicle home from Savannah, GA with a trans failsafe message. Once it got going, it was fine. The engine is strong, so I may just deal with any motor issues later on if the project is a success! It does have chain rattle noise on start-up. So, let’s get going!

Here it is!! Famous “1” as I started calling them by their production year. I have 1, 2, 4, and 6 currently.





I started pulling apart the stuff that needed to come off... Found this... Little things will be addressed!







Blurry. Sorry!



This is a mess!! My CDO is getting to me here...



AND WHAT IS THIS!?





And one of the biggest reasons why to convert the pre-facelift versions! The engine and trans harnesses are divided! The post-facelift versions have all the wires combined in one loom. UGH!!!



Going down to the trans!! All this is going away except for a few wires needed!



This is where the clutch hydraulics gets it brake fluid from. Cut the melted crimp and attach your hose. Remove the round circle and the plug in the firewall for your hose. I’ll grab the length as time goes on. I got the 10m section (I think) from ECS...



Soon to have a three-pedal design! I have two brake/clutch assemblies already made up.



Comfort seats!! Wish it had Sport Package instead!!





Options!!



This was the first thing I noticed. This arm for the shifter was not going into the slot for “D” easily. Also note this is the pre-updated shifter for gear selection. This one has the gear “+” going forward and gear “-“ going backwards.







That is all I have so far... I’ll try to keep the pictures updated as this progresses... I did the headlights already since I can’t do much after work. I’m off tomorrow, so I should be able to get more done.

I wish I had the pictures of the arm for the shifter! It is incredibly LONG by comparison to other BMW's I've worked with. I will have to fabricate something as the 3.0L trans and the 540i trans have different mounting designs for this arm. I'll try to get those pictures tomorrow. I can weld aluminium, but I'm trying to get this project "do-able" for most DIY'ers!!!

Cheers!!!

[BimmerM3inGA]

Oh yeah! Here we go!

[squidzilla]

Nice to see you making some progress. And thanks for thinking of us DIY types that can not weld. I really appreciate you doing this thread.

[williamx5]

Good Day!

Here is the latest I have on the project... I’ve come to the conclusion that this is going to be more involved than most DIY’ers are willing to go. I found out tonight that to do this correctly, I would need to pull the dash, all heating and A/C components from the interior, seats, and center console. All that is so I can get the front section of carpet out, just to install the hydraulic line for the clutch...

But, let’s keep moving on to see how much labor is going to be involved…

Here is the arm... Incredibly long!









The easy part... Pulling the brake assembly to install the assembly already completed. Here is a “Before” shot!!



Pulling this for future upgrade...



I find it easier to leave this connected and just pull the sensor from the adjuster housing...





With these, you pull the red part out and depress the tabs to remove from the holder...



I initially did not pull the metal plate, but dealing with that area so much, I decided it was better to remove it. You have to pull the headlight switch to access one of the screws, but the other five are easily seen. Here the metal panel is out...

This is the unfinished “After” shot...



I must say, this was easier to get out than I have seen on the internet (we all know everything is true on the internet!)... It was stated that the dash needed to be removed to get the center console out. Proof that it doesn’t...



I can go over how to remove it if anyone needs me to.

I will also say that getting this shifter out is more of a pain than it’s worth to leave the shifter cable in place... Better to just remove the shifter and cable together, unless there is some secret method I am unaware of...



Gotta remove this to pull the carpet... Push the tab and slide it to the left... Be careful of the connector!! Upon re-assembly, make sure the wire is out of the way... This one was a little crushed by the mounting plate...







Okay, I don’t want to hear anything about what I did here!!!! In the essence of time, I decided to cut the carpet for ease of removal! Any future modifications will be done the long “correct” way!! It was difficult, but I have access to a rotary knife so it wasn’t that bad...







Oddly, I cut this in ALMOST the correct spot for the hydraulics to go thru the body... The plug and hole seems to be a little bit bigger than it should be. The plug on the line goes easily thru the body. I might be missing something and will look into it more later.







The carpet has a depression for the tube.



That little bump is where the line routes... There is also a depression in the section I removed...



This is connected... One zip tie and this part will be completed... Carpet install and I get to move on to better areas of the project!! Like transmission removal!!







And the hose I used was exactly 365mm long. I think you can get away with using something in that ballpark!



Some things I do need to get! A driver’s seat bottom. A center console arm rest (mine has a factory phone and one hinge is broken), and a left rear exterior door handle.

I’m going to try to pull the transmission tomorrow. I don’t have a clutch arm, throw out bearing, clutch arm pivot pin, or pilot bearing... So, while I can install the flywheel, the rest will have to wait.

Okay!! Cheers for now!! More to come!!