$1000? Sheesh. I can get the same box from a local yard for $5-600...

If I get lucky enough to get one show up in the PIY, it will cost me $157.48 plus environmental fee... Minus military discount... I just have to have time to pull the trans if one shows up... I let two get away because I already had one in my garage... This was a while back, before I knew I would need all the ones I could get my hands on... If this conversion works... Wink, Wink!!!

I will be stocking up on all these parts needed to do the conversion... So, if someone wants it done, I will have everything set out and ready to install to make the conversion quicker...

As it turns out, I might be forced to convert the 2004 first... I just can't seem to get that 6hp26 to cooperate!! And I am getting tired of draining the fluid to swap something on the valve body... I'm going to give it another week... If it is still doing the same thing, it is getting pulled in favor of a manual trans... I have the pedal assembly all ready to go... A few more items to get or modify... I was looking at the trans cross member yesterday when I was finishing up the rebuilt valve body install... It might not be as difficult as I had originally figured... It is a shame that I might convert "4" over before "2" (2004 4.4L vs 2002 4.6is; I have three so I named them)... I have a transmission ready to get installed in "2"... Hmmmmmmmmm, I wonder if it will fit in "4"??

Well, so much for that idea, not that I was really serious... It appears I will need to get a bigger garage if I am going to have conversion kits ready to install... The E39 540i parts and the E60 545i parts are totally different, with the exception of the pivot pin and the output clutch cylinder (on trans)... clutch sets, flywheels, clutch forks, yada yada... are all different... I'm going to need twice as many parts for the two different versions...

Well, I'm going to see how the first one goes before I purchase a bigger shop... LOL!!

Cheers!!

Nice to see someone else exploring this. I made the decision as well for my 4.6is, but I have many other projects ahead of this one. I have an e39 6spd trans and pedals, and the hydraulics/shift linkage from the 3.0 as well as a UUC e53 shifter. I've swapped four 540i's so far, and one 525iaT to an M5 touring, so the conversion should be simple. The most difficult part will be measuring the driveshaft and sending it out to be lengthened.

One thing it will certainly need (IMO) is an LSD in the rear. The e30, e36 (M), e28, e34, e23, e24 and possibly others have available 188mm LSD's in a variety of gearing. I feel the 3.64 in the 4.4, and especially the 3.91 in the 4.6 would be too short for the 6spd manual... Considering the 540i/6 came with a 2.93 and the M5 with a 3.15. The e34 535i/5 came with a 3.46 LSD, and the 92-95 525i/5's came with a 3.23 LSD, which would be just a *hair* shorter than the e39 m5's 3.15 ratio. Both should allow the X to get up and move just fine, and would make them quite a bit more economical on the highway.

My E39 M5 has the Dinan 3.45 LSD and its a great match up for the manual transmission. So I wouldn't hesitate to consider the 3.45, 3.46 diff for the X5 conversion.

Good day!!

You bring up an excellent point... I have the 4.4L in "4" and the 4.6L in "2"... I am not going to type this out loud, so everyone cover their ears, but I think the trans in "4" is getting better... Maybe air purging out of all the little places in the valve body... and it's re-learning all over again... It didn't really act up on the way home... It shifts REALLY REALLY quickly thru first, second, and third... It just wants to be in fourth for some reason... I haven't taken it to "SPORT" mode yet... Shhhhhh.... We don't want to frighten it...

SOOOOOO.... If I do "2" first... I think I will have to swap in the 4.4L rear diff for now... Only because I have to do some extensive research as to what I can do with the housing and avail parts from other BMW's... No other BMW rear diff will just bolt in like in the days of old... and nearly every bigger motor base model had an LSD option avail prior to 96... We lose the LSD, but gain ASC or DSC... Ummmmmmmm....... But, I would love to have the 3.23 or something around that... I had swapped in the 3.15 in my second 540i, and it was a huge improvement to many things!!

I'm off to sleep...

Cheers all!!!

Just wondering why you would want to go down in the ratio? I think you would lose some low end performance. I know it boils down to final drive ratios but I don't see the advantage of going with small rear gears. With the addition of the extra gear for the manny swap I would think it would balance it out. But again without doing the calculations no way of knowing. Plus a deeper gear will make that low end torque a lot of fun. I do agree a LSD would be an awesome addition.

I was wondering the same thing. I haven't looked up the ratios in the 5 speed automatic in the 4.6is and compared them to the 540i 6MT, but I had an expectation that the post-swap 6th gear would calm things down on the highway. Maybe I'm wrong? But yes, the LSD would be nice to have.

Good day!!

Well, it is all about quick or fast... I wouldn't mind having both all the time, but with hard rear diffs, we have to pick... It would be nice to have a rear diff we can change like our transmissions, but that is probably some time away... I would love to have the 3.91 all the time, but it all comes down to fun versus usefulness... I'm running over 3000 RPM's on the highway cruising with traffic... It is just a little much for me... The final gear for the 5hp24 is 0.80 (over drive)... The final gear for the 540i 6MT is 0.828 (over drive)... So, they would be nearly identical at cruising speed... However, off the line the 5HP has a first gear of 3.57 and the 6MT has 4.227... So, first gear for the 6MT would be almost invisible using the 3.91 rear diff currently in the 4.6is... If I drop the rear diff to the 3.64 (currently in the 4.4L) or the 3.23 out of a 2005 525i (if it will work), I would get the best (or better) of both worlds... The additional gears would make use of the higher rear diff ratio, but still have lower RPM's cruising with traffic...

How many of yous did I totally confuse?

Thanks again E34PLAY for bringing this up as it needs to be something to consider and be on my radar for a working final product...

Cheers all!!

So checked out one of the jeep sites i use. Grimmjeeper.com for those that want to see. Plugged in the info and honestly the only advantage you'd see is higher top speed 170 vs 158 and higher speeds at given rpms. 3.91 will be at 2.6k at 70mph and 3.64 will be 2.5k. Personally, I wouldnt see the advantage of loosing low end for marginal rpm drop at cruising speeds, but just my 2cents.

True, top speed would be higher, which is one of the things I want... But, I have a lead foot and don't usually follow the posted speed limits like most of the other people cruising the highway... I don't do 95 in a 70, but cruising with traffic, I want the RPM's to be a little closer to the 2000 mark than above 3000...

Additionally, the item that really stands out, that the calculator on the Jeep site can't tell you, is how fast you will burn thru first gear... It will be a mere blip before you need to shift into second... If you figure the 4.227 for first and 3.91 rear, your top speed at 5K RPM's is like 12MPH... Honestly, I'm totally guessing on the 12 MPH... But you get the idea... The 4.6is has enough torque to still get you going rather quickly with the 3.23 or 3.64 gears... Heck, the 540i/6 is a 4.4L and a final drive of 2.81... I still have a huge grin every time I test the traction control on my E39...

In the end, to each his own... I would rather go fast slower, but go faster in the end... Others like to go fast quickly, but not so fast in the end... Ummmmmmmm!! WAIT!!! What were we talking about again?!

Cheers!!