My 4.6is project!!

[williamx5]

Good day all!!

Here is the story on my new (to me) 2002 Imola Red 4.6is... I found this on craigslist a good month or so ago.









Little bit of damage that I hope will fix up like new!!!



I was looking for a project vehicle to do a manual trans swap from a 540i. This one "needed a trans" from what the PO stated. The asking price was a little more than I wanted to put into the initial vehicle knowing it was going to need a bunch more items for the conversion. But, I liked the idea of converting an already sporty version X5. I went to look at it and decided to make the purchase with a lowered agreed price of $3000. I put a down payment of $600 and came back the next day with my tow dolly.


I pulled the front drive shaft and found the problem the X5 was having.


I looked on ebay as soon as I got home for a transfer case (TC) and front drive shaft (DS). Snow storm hit and delayed getting the parts by a day or so. Tucked away during the snow storm...



The seller was great to deal with! Super nice and helpful! And check out the packaging done to the new (to me) TC!! Gotta love it!!







As luck would have it, I found out the DS that was in the X when I purchased it was the modified version. I don't know how many individuals are making these, but I'll tell you a little story about the one guy I found on ebay selling the modified version in a minute. This is the failed DS and the new used one I got with the TC... A point about the failed DS... There was no sealing sleeve (sitting on top of the two DS)... Would it have lasted longer if the sleeve was there? I greased up the new used one and made sure the used sleeve was as round as I could get it!!



Both have spline wear (one far worse than the other)!! HOWEVER, the longer one that was in my X when purchased must be made of softer metal than the TC output gear because there was virtually NO damage to the splines!! I installed the new used ORIGINAL version DS and took it for a test drive. YEP! $3000 for the vehicle and a used DS to put it back on the road.

That's all for now!! More to come!!

Cheers!!

[williamx5]

Good day all!

Okay! A few more things... I needed to get a rear tag light/hatch release board. The one that was originally in the X was missing a light cover and had corroded the board so bad the release switch wasn't working. I found a NEW assembly that had a silver body color. I pulled the part I needed and installed in on my original red exterior part. Works great!!!







Here is the short story about the individual I found on ebay selling the extended front DS. I have my failed one sitting in the garage. I have the new one on the way. So, I decided to get with this seller and see if he wanted my old one to fix up and sell. He stated he'd give me $50 for the DS and pay me after he received it. Okay, no worries! How do I get it to him, I inquired. Just send it to my address of blah blah blah and I'll give you an extra ten bucks. I inquired about a pre-paid shipping label and that I was taking all the risk. He went on to say that I shouldn't have contacted him if I didn't trust him and he thanked me for wasting his time. I don't know!! If I had a chance to make $250 bucks off a $60 investment, I think I would have gambled the ten bucks to get the item...

Another interesting thing I discovered was the PO filed down the locking lugs that hold the door glass to the plastic holder... The original holder broke, but instead of getting new holders, he/she filed down the lug to fit tighter. So, when I got my new holders, the lug wouldn't bottom out and stay snug. It would just get to the point of breaking the new holder. UGH!! AND, there were only three door panel clips holding the door panel on.

I cleaned up the X yesterday!! Oh so much better... I'll get pictures today. But an interesting thing happened to the better half and I on the way home from dinner. The water pump bearings failed about a mile from home. I lost the belt in the process. No PS, Alt, or cooling. OUCH! Managed to get home by coasting most of the way. I get to add this to my list as soon as I get the pump!!





These were down in the fan shroud. One of the bearings melted into the plastic...



There is also a clunk on the right front I need to investigate... So, more to come!!!

Cheers for now!!

[dannyzabolotny]

Haha wow, you got that for even less than what I paid for my 4.6. How many miles are on it? Looks like it has a fair few issues but judging by your posts its in good hands and will be running top notch in no time!

[williamx5]

Originally Posted by dannyzabolotny

Haha wow, you got that for even less than what I paid for my 4.6. How many miles are on it? Looks like it has a fair few issues but judging by your posts its in good hands and will be running top notch in no time!

Good day Danny!!

I think it has around 169K miles... It is hard to read and I will be addressing that and the midi pixel issue soon!!

Here are some more pictures...

I have only washed the outside. No wax yet. I have a good feeling the paint will really come alive after I wax it. Unfortunately, that will have to wait until my next days off...





The M-textured interior did come fairly clean. I have to put the BMW rubber floor mats back and get a few more touch-up spots taken care of! There is a silver paint something or other in various places inside the X. Very odd!!







I got with the seller of the TC and DS I got... Merdedesoriginalparts let me use their ebay user name in here... I do recommend them as they are extremely easy to deal with for parts you may need. And, NO! I'm not getting kick-backs or anything! Just passing on a good source for used parts...

Well, that is all I have for now... I'll try to get this pump done ASAP so I can get it back out on the road!! Only drove it to dinner and back last night and I can't wait to drive it again!!

Cheers all!!!

[williamx5]

Good day all!!

Well, I got the water pump out and have the new one ready... I forgot to get the O-rings for the tubes that go to the rear of the motor... UGH!! Oh well...

So, I am also making the kidneys black instead of the chrome and silver like in the pictures above... So, to match everything I am not sure what way to go with this... Do I match the trim around the windows and make them glossy black, or make them like the cowl intakes and make them flat black...

What do you have if not stock?? I'll get some new pictures posted up soon... I've been crazy busy trying to get everything back to operational condition...

Oh, I almost forgot!! I got extremely lucky yesterday... I pulled up the local pull-it-yard and found they had a couple new X5's enter the yard... One had the OEM factory running boards like the ones on my better half's 2004... I figured they would have been gone by the time I got there (5 days later), but to my surprise they were still there... I got the right side axle, hub, and both lower control arms in one complete assembly... The hardest part of getting it out was moving the strut to the side to remove the axle shaft from the diff/oil pan... I also got the sway bar end link (which I think is what was causing my clunking)... I also got the water cooled alternator, two CD players (dash), lug wrench (I had the 17mm version for some reason), water pump with fan clutch (4 bolt version), air intake that sits flat right under the front of the hood (mine was broken), rear trailer hitch cover, older version kidneys (black centers), original CD holder thing for the center console, two front PDC sensors, headlight mounts for the E39 (mine are in pieces), and an original jack (older version)... All for the grand total of $229.57...

Cheers for now!!

[dannyzabolotny]

I'd go with matte black, to match the body trims and bumpers. That combo looks pretty good on an Imola Red E39 M5, so I can't see why it wouldn't look good on an Imola Red 4.6.

[williamx5]

That is what I am thinking too Danny!! I had my first 540i sport with the manual trans with the matte black kidney's... It was a black car, so it really looked sweet with the raised M5 version instead of the flush chrome version... And I put the OEM Hella angel eye's from a 2001 on it too... Might change the current 540i6 over if this one works out well...

Thanks!!

Cheers!!

[dannyzabolotny]

I also ordered matte black kidney grilles from ECS for my Sapphire Black Metallic 4.6, so we'll see how those look once they arrive

[williamx5]

Originally Posted by dannyzabolotny

I also ordered matte black kidney grilles from ECS for my Sapphire Black Metallic 4.6, so we'll see how those look once they arrive

I probably should have done that... Much easier... I had to go the cheap route... I took the chrome off (just the front side) the originals I got from the yard the other day and painted the gray plastic matte black... I also painted the center strips, but doubt I had to... I'll grab some pictures after I put them on tomorrow morning after I get off work...

Cheers!!!

[ZAX5]

Love the project
Lots of small things to fix and then have a lovely X

Like the colour.