01 X5 4.4I 6spd Manual

[theblue]

I would like a 7 speed (or more) twin clutch if I could have anything in my X5. no desire to have it as a true manual.

[Nick P]

Originally Posted by theblue

I would like a 7 speed (or more) twin clutch if I could have anything in my X5. no desire to have it as a true manual.

Actually, we can convert this set up in to SMG 2 quite easily - we need the catuators and ECU for the drivelogic and we can either put more durable synchromeshs into the current gearbox or just take the M3 E46 gearbox, which now can be bolted on the transfercase with no problems. Just the SMG will stress the transfercase to much, in my opinion. But it's doable with no problems at all.

Regarding 7 or more gears - the stock S6S gear ratios are very close, whereat the 7 or 8 gear automatized-shift boxes usually have only 4 gears for actual acceleration, the other are for better gas milage.

So, comapred to stock 5-speed auto we now have a very usable 4th gear to fill the gap in acceleration, comapred to auto. 5th gear is now as the 4th on auto (1:1) and the 6th is a bit shorter, than 5th gear on auto.

Here are the top speeds in each gear in comparison (in kph):

Aut. 4.6is 3.91 315/35/20
U/min 1000 2000 3000 4000 5000 6000 6500 6800 6900 7000
1. 9.5 18.9 28.4 37.8 47.3 56.7 61.4 64.3 65.2 66.2
2. 15.3 30.7 46 61.4 76.7 92.1 99.7 104.3 105.9 107.4
3. 22.4 44.9 67.3 89.7 112.2 134.6 145.8 152.5 154.8 157
4. 33.8 67.5 101.3 135 168.8 202.6 219.4 229.6 232.9 236.3
5. 42 84 126 168 209.9 251.9 272.9 285.5 289.7 293.9

Getrag 3.91 315/35/20
U/min 1000 2000 3000 4000 5000 6000 6500 6800 6900 7000
1. 8 16 24 31.9 39.9 47.9 51.9 54.3 55.1 55.9
2. 13.4 26.7 40.1 53.4 66.8 80.1 86.8 90.8 92.1 93.5
3. 20.2 40.5 60.7 80.9 101.1 121.4 131.5 137.5 139.6 141.6
4. 27.5 55.1 82.6 110.1 137.7 165.2 179 187.2 190 192.8
5. 33.8 67.5 101.3 135 168.8 202.6 219.4 229.6 232.9 236.3
6. 40.8 81.5 122.3 163.1 203.9 244.6 265 277.3 281.3 285.4


I personally prefer manual gearboxes only because I can controll the stress and so also the durability just by my driving style, which is very relevant by cars getting old.

Now, with clutch engagement, the transfer case should last much longer, without abrupt stress caused by auto especially after changing from "R" to "D" on auto.

Here's my last picture I've done so far (please mind, the fornt driveshaft is off)

[theblue]

hated my friend's SMG M3 compared to my DSG A3 but that's pretty cool that you could go to SMG using parts of the shelf.

[SlickGT1]

I so really, really want to be able to do this. Do you think this is doable on the 4.8is?

Also, how did you get rid of all the transmission faults in the computers? The car must be missing a bunch of stuff.

[Nick P]

Originally Posted by SlickGT1

I so really, really want to be able to do this. Do you think this is doable on the 4.8is?

Also, how did you get rid of all the transmission faults in the computers? The car must be missing a bunch of stuff.

I'm actually not a big specialist in electronics, there's a lot of people beyond this little project, so I'm just 1/100 part, just the car's mine and I was looking for the right people for almost a year and first of all I had a tenacious wish to accomplish it.

We were able to start the engine just by shoting down the pin 8 on EWS, which is responsible for the clutch, but than we had all the lights on and nothing worked. Still the engine surprisingly ran on full power. We called a guy, who solved everything even with stock harness by tipping some default values to ECU, I don't exactly know what he's done, I wasn't even there, as he done all the stuff, but for him it was a 30 min task.

Regarding similar conversion on 4.8is, I don't know about the logic unit of xdrive, I think you have to go to a good programmer (like I did), which can transfer the data from the x-drive ECU taken from X3 manual and adapt them for X5. I

It's doable even with x-dirve, but it's an easier task with full mechanical unit like NV125 on M62-powered X5s.

The other thing is, if you intend to do it in USA, only the CAD developement of the connecting haousing will cost you a fortune, producing of casting moulds even with given CAD data will cost you another fortune....

So I did both in Russia (I'm russian by nationality).

But it wasn't possible in Russia, to produce the connecting shaft, because the slots on the shaft must be hardened by very special process, I let do one and tested it on a special machine and it was broken, because the metal in russia is shitty and the shaft needs the degree of hardening of 60, which wasn't realizable in Russia.

I met a guy here in Germany, who helped me alot, but even his first prototype was broken under static stress of 550 Nm, which wasn't bad at all, but the current one is capable to hold more than 600 Nm.

If you'd like to do the same thing I can provide you a similar connecting shaft if you give me a blueprint, but that's the most I can do in case of x-dirve and GS6-53BZ (545i) gearbox. But it's doable, of you really want it.

Regards,

Nick

[Skyline]

>Nick

So it looks like the problem was not getting a tranny that would bolt up to the engine, but getting the tailshaft to mate with the TC???

Is that adapter plate between the tranny and TC?

And the connecting shaft you mention is the input shaft of the TC?

[Nick P]

Originally Posted by Skyline

>Nick

So it looks like the problem was not getting a tranny that would bolt up to the engine, but getting the tailshaft to mate with the TC???

Is that adapter plate between the tranny and TC?

And the connecting shaft you mention is the input shaft of the TC?

The gearbox bolts simply on all M60, M62 and S62 engines, while there never was any tailshaft or rear housing offered by BMW to connect the Getrag S6S gearbox with the transfercase.

The thing between tranny and TC is rather a housing, than plate. Unfortunately I had to discover, it's not possible to mill this part from a aluminium bulge, but only cast it, due to the very complex geometry and close space between transmission and bodywork. Furthermore, the adapter housing had to fit very tight to the gearboxes housing, to achiive the needed rigidity of connection.

Connecting shaft is the input shaft, welded on adapter to be bolted on the stock exit flange of Getrag.

Regards,

Nick

[SlickGT1]

Well you see, that is one less problem. I am Russian too. Privet.

Yes, if this is doable, I am seriously going to research doing this here. My main problem is the transfer case, and the millions of sensors. I am pretty sure I can remove the transmission by coding. I am also pretty sure everything can be coded up. Just can't even imagine the task.

So the transmission bolted up to the car and engine no problem, correct?

Then I figure, well based on the pic, that you needed an adapter plate for the Transfer Case.

Which connecting shaft are you talking about?

[Green Dragon]

Edit:Sorry for the delayed posting. Some of my questions were answered above.

Nick,
Impressive Buddy!

Is the rear 1/3 of the transmission outer case, a custom cast or from another gear box? I'm sure you looked at adapting everything you could from a manual 3.0/3.0d, including stuff like that. I think the engine management systems are different on the v8's, however the main wire harness is probably the same.

Agree with Skyline, looks like an adapter-plate to mate the the transfer-case with the tranny case.

With my e36 manual conversion, jumping and/or bypassing pins is what I did manipulate the computers. I left the automatic transmission computer intact. Most of the manipulation took place at wiring harness connecting to the old auto shifter. Sounds like it was a similar approach. I was able to trick the system and retain cruise control, and induce the clutch safety start.

However, this is more involved/complicated to manipulate than what I did. Full credit to you and your tenacity, to your mechanics/electrical engineers. Genius. Keep throwing us info!

[Nick P]

Originally Posted by SlickGT1

Well you see, that is one less problem. I am Russian too. Privet.

Yes, if this is doable, I am seriously going to research doing this here. My main problem is the transfer case, and the millions of sensors. I am pretty sure I can remove the transmission by coding. I am also pretty sure everything can be coded up. Just can't even imagine the task.

So the transmission bolted up to the car and engine no problem, correct?

Then I figure, well based on the pic, that you needed an adapter plate for the Transfer Case.

Which connecting shaft are you talking about?

Electronics and sensors are nothing compared to custom fabrication, you need an adapter housing which will cost you more than 2 used 4,8is to produce if you're gonna do it in outside Russia.

First of all you have to buy an 545i gearbox, take the rear part of housing off and bring it to 3D scanner. Now you have to import the data into CAD programm, you'll see a huge band of points, than you have to join the points to surfaces and join them together, you will do it for inner and outer surfaces twice. So you get the shape of your adapter housing. Than you will let produce a plastic modell to try it out on your rear gearbox housing and transfercase. If necessary, you have to do some corrections in CAD after that you have to cast your master form made of silicone. After that you can finally produce your adapter housing of aluminium alloy. It will look cheap and dirty, after that you have to correct all the casting mistakes and make all needed holes, brackets and so on. Now you have your adapter housing.

Just the producing of master form costs 35 000 Euro in Germany, without developing of CAD modell. The casting itself isn't expensive.

Now, if you look at your manual tranny - threre's an exit flange, where usually the propshaft is bolted on - so, how you're gonna connect it with your transfercase?

The connecting shaft is needed, which is also the input shaft into the transfer case. The hardening grade of this input shaft is 60 (just for comparison - the highest hardening grade, the russian high-tech industry can acchieve is 42) and the slots of the stock input shaft have even some special hardening. There was 3 prototypes made and these could'n last the stress, I was aiming to expect from the drivetrain.

The last input schaft was made with technology I even don't know about and I also won't tell you any details about (I was asked for)

So now after 11 months, you have your custom made housing and connecting shaft. Thats the right time to think about electronics, which was done in 30 min.