My 4.6is project!!
 

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.

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

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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...

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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!!

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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!!

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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!!

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!!!

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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!!

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

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

Cheers for now!!

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...

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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!!

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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!!!

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!!

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.

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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!!

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!!!

Proejct red
 

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

Like the colour.

Good day all!!!

Here is the update I've been wanting to post for some time... I finally have a few hours to deal with photobucket loading pictures and such... So, lets get started...

I had a clunk in the right front after I got the drive shaft installed... I dug in and found the outer CV joint boot was completely split all the way around... Grease covered everything... I had a little play in the lower control arm as well... I decided to get the whole assembly from the pull-it-yard... Both control arms, spindle, hub, and axle shaft... I am not sure why, but I unbolted the sway bar end link... I didn't need to touch the sway bar end link to get the parts I wanted, but since I had it half way out, I took it home with me... Good thing I did too!! It ended up being the clunking noise... The original was about ready to let go on me...

All the parts I grabbed that day!! OEM running boards and fender parts to go with it... Water pump with fan and clutch (interesting story on that in a few), two in-dash CD players, right front assy I needed, rear bumper hitch cover, headlight mounting for my 540i, water cooled alternator, air intake (mine was broken), and various other smaller items...

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Not a lot of clearance here... I pulled the strut assy forward a little to get the axle out easier...

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And the two, side by side... The one pulled from the yard had the 4.4L, but smaller brakes... The hub had two locating pins that I needed to cut off and grind smooth... I couldn't hammer them in or pull them out...

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Okay, here is the story on the water pump... I pulled it knowing mine was toast... And for 7 bucks, it was worth the effort to have a spare... And I pulled the fan and clutch with it... It isn't as hard as some would think... Well, I got my brand new pump the next day, so I didn't use the aftermarket one I pulled from the yard... HOWEVER, my original pulley was cracked and I didn't want it tearing up my new belt... Or worse, exploding and taking a lot more out with it... So, I had a good one on the pull-it-yard pump I got... I tried to get the clutch off the pump for about 30 minutes... I know it has left-handed threads... So, I'm guessing the mechanic that installed the pump figured it needed to be tightened beyond removal... I had to cut the fan to get the clutch opened up to cut the shaft so I could get the pulley... I later took my 1/2 drive IR impact gun to get the nub off the pump... It took a constant trigger pull of the impact about 45 seconds to free the nub... Insane!!!

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Here is the plastic tube replacement I did... I was installing the top radiator hose and pulled the air bleed hose to the tank when it just snapped on me... It broke a couple more time just pulling it from the mounting points on the tank... Very brittle!!! So, I pulled the clamps and broken parts from the existing hoses and installed this NON-FUEL INJECTED fuel line... Able to hold 50PSI, so I figured it would be good... We'll see!! There was just enough space to route in between the tank and the holder...

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And now for the kidneys... Here are some of the originals and one I tried with shiny black and finally what I settled for... I need to take some better pictures when it isn't so gloomy outside... Maybe tomorrow morning...

Original with chrome being removed... Not difficult, just time consuming...

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Cleaned of chrome... Gray not that appealing...

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Bad picture of shinny black... Didn't take well and I didn't like it at all...

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OEM and then with the new look!!! Need better pictures!! My apologies!!

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Well, that is all I have for now... I want to pull the front bumper next to find out how much damage was done in the right front corner... I'll try to get to that in the next couple days!!

I did find out yesterday that I can roll up the windows from my house with the remote... PO must have programmed it because I don't think any US models were allowed to do that option... Additionally, my son just got a 330i that also has that feature active... It is indeed quite useful!!!

Cheers for now!!!

Nice junkyard haul! I never see any X5's in the junkyards here, haha. If one ever shows up it'll likely get destroyed by the junkyard vultures in a day or two, they just use crowbars to get everything out.

I'm glad you got the clunk all sorted out. The black painted grilles look a lot better with the Imola Red, that's for sure.

The window roll-down and roll-up are features that can be programmed by a dealer or by yourself if you have PA Soft/BMW Scanner 1.4. I have that on my laptop and the option is called "convenience opening/convenience closing" in the IKE section. I disabled that on mine, along with the daytime running lights. I don't like having the windows roll down if I accidentally hold down the unlock button too long— the regulators are made of cardboard already, no need to stress them further!

nice buy. I was looking at this to buy but purchased another from Fayetteville, NC.

what junkyard are you going to? I'm Greenville local and there aren't any x5s here to pull from

Good day!! Oh, they do the same to the vehicles here too... It is a shame!! The X5 I got the right front parts from had been on the yard for one day... Looked like it had been there for a month...

I have the computer and software with just my K+DCAN cable... I'm waiting on my ICOM so I can program all the modules... I was just surprised to see it already had that option coded... I have to code or program my LCM... The PO replaced it without programming... It is interesting... My lights work, but I don't have status on the cluster and I don't have to turn the lights off when I shut the car down... Nothing stays on... My hazards blink one slow, two fast, one slow and repeat... Different!!


Thanks!! Let's see yours!! Probably doesn't need as much as this one!

I found one in the Greenville yard a couple weeks ago... Guess they move their inventory out faster... There are either two or four in the Greer yard... LKQ pull-a-part... Little more expensive, as far as pull-a-parts go... But!!

Cheers!!!

Wow! We aren't too far away. I'm in Anderson SC. Nice X5 BTW. I just checked out the u pull it yard and it looks as if they have a few 525i's. I need to get up that way and see if there's anything good left on them. I need a couple of replacement wheels for my 528i so I can get mine refinished.

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wow really small world. I live in Simpsonville and used to live 5 min from LKQ. ill start a thread soon on mine

Absolutely!! What wheels do you have or do you need any replacement wheels available? I'm going out there again on Wednesday... I can look for some wheels... and anything else you may need...

I'm pretty sure I need the bumper frame... It is great that they are all the same!! I actually pulled a perfect one off the X5 I got the water pump from...

That would be great!! What did you end up getting??

Cheers!!!

Good day all!!

Well, I just ordered the Lifeguard-5 and filter/pan gasket set... It will be here in a couple weeks... Got the 12 Liters of LG-5 for $16.16 each... It was the best price I could find... The Meistersatz pan gasket and filter were $34.80... Again, the best price I could find for quality stuff... I think WIX had a set that was a bit cheaper, but I've heard mixed reviews about WIX...

I may have to put the trip to the yard off until Thursday... I have to take a trip to NC on Wednesday... So, if you have parts you need, you have another day to get back to me...

Cheers all!!!

Sorry to burst your bubble but Filtran is the best filter to use with the 5HP24 transmission. Cheaper filters often cause the transmission to whine. Filtran is what comes in the 5HP24 from the factory, and that's the only filter I'll ever use as a replacement. I've used Filtran filters on every 5HP24 fluid + filter change so far with great success. My 540i Touring has 184k miles on the original transmission and it's still shifting pretty well thanks to a well-maintained transmission.

No bubble bursting here!! That's why I love these forums... Experience trumps what the brochure says!! I'll look them up... This filter is only staying in the trans for about 100 miles... I am doing the fluid change in steps... The first fluid drain will get the new filter as I imagine the one in there is original... I'll get the Filtran filter for the final drain and fill... Thanks for sharing!!!

Cheers!!

Good day all!!

Well, I didn't get what I wanted from the pull-it-yard (PIY)... I pulled the bumper this morning so I would know what I needed to get... It was actually worse than I initially figured... There are mainly scratches and a little paint rubbed off on the bumper cover... I didn't figure there was extensive damage to the bumper frame... It was really hard to get a good shot of the damage, but I hope yous can see it...

This is the shot in the garage with the flashlight... Not enought light...

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Outside...

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And the good side...

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Well, I got the Durango hooked up to the corner and I cranked on the ratchet pull strap thing... I pulled the bumper out some, but obviously I wouldn't be able to get it perfect... The bumper was actually missing almost all the mounting hardware... It is a good thing I usually put all hardware in my pocket when I'm at the PIY... I installed all the missing washers and mounting hardware... There were still some points that didn't line up... I'll have to deal with body shell points after I get the new bumper... But for now, I have it almost invisible... I need a fender clip that secures the top corner of the bumper cover... The PO had a screw holding it in place... I think I'll get the plastic clip tomorrow...

Unfortunately, I am missing the tow hook covers... I didn't even notice they weren't apart of the outer PDC sensors... I installed those too, but still get a fault status on the module... UGH!!

That's it for now... It was too dark to get good pictures when I finished... I'll get those tomorrow too...

Cheers all!!

Any plans to convert this to a manual transmission down the road?

I need some tan seat control bezels for the sides of the seat and I need two of the wheels that it looked like they had in the pics on that 525i on the website. I unfortunately haven't had the time to get up there and pull some stuff. I just ordered some rotors and pads along with some tie rods and boots from fcp euro. I am going to be on the lookout for either a 3 series to work on next for a daily driver or either an x5 like you've purchased there pretty soon. I bought the 528 for my wife and fell in love after driving it for a short distance. It's been some work though. I've already put a new fan shroud on, intake gasket, replaced the vacuum lines, changed the oil and filter, and put some new plugs in. I'm going to do a suspension refresh next and windshield molding. I want to get the wheels repaired or replaced soon too. So much stuff, but I want to have a nice car that I intend on driving for quite a while. Ppl say they sink money into these cars,but after driving one, i can see why.
Thanks to all on this forum for all the help for sure. It's a great group of ppl around here with alot of knowledge, thats for sure. Good luck with your x5. I'm subscribed so I can keep up with yours to see what I'm getting into if I decide to go with that over the 3 series.

Sent from my SM-N920P using Tapatalk

Good day!

Absolutely! I'm still sourcing all the used parts... The 3.0 manual parts are hard to come by unless I buy the whole vehicle... I found all the parts needed in one auction, but the seller had everything in an auto to manual swap kit... but for the 3.0... He didn'twant to break up the kit and sell me just the stuff I wanted... So.... We wait...

Cheers!

Good day!!

Apologies for the delay reply... I've been trying to catch up on my to-do list... I will look for those seat parts... Mine were broken on my 98 540i6, but my 2001 540i6 are still holding fine... About the wheels... As it turns out, I happen to have a set of staggered five spokes that came stock on my 2001... They are NOT, repeat NOT perfect... I got a cheap set of identical wheels that were in better condition to use... You wanna use or buy them to use until you get yours repaired or whatever?? I gotta go back to the PIY as soon as they get another X5!! I need that headlight and bumper frame support that I missed out on the last time I was there...

Cheers!!!

Good day all!!

I decided to dedicate some time to the 4.6is today... The better half's 4.4L is still proving to be somewhat of a challenge with this transmission EGS module...

I decided to put the running boards on that I picked up at the Pull It Yard (PIY) the other day... Here is what I have for the right side... (time to deal with slow photobucket!! This is the worst part about sharing!! I have to find a better photo hosting site!! Photobucket just sucks the life out of my computer!! Nothing runs with photobucket pulled up!! Rant over!!)

Finally!! This is the re-usable trim rivet... I had these on all four fenders!! The bottom shields had the similar kind that had a flush plastic pin that gets pushed through when needing to remove... You can reuse them if you can get the pin back... I will find more of this kind to go in all the locations needed...

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My fender damage... I hope this will all get back to normal when I get my bumper support and new (used) headlight...

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After you pull the plastic rivets from the bottom, just lift up on this and it will pop free of the smaller rail...

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The rail...

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Bolts... Slightly longer with a flat washer...

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Everything off...

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Marked LH and RH on the insides... Rear has a cut-out for the rear door... Or will have the fender flare if already from a 4.6is or 4.8is... I have to make the slots for my fender flare... That will soon follow this...

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Don't forget to transfer this pin and it is VERY difficult to get in place with the running board already installed... I'm going to try to put the fender parts on first and then the running board...

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Almost done... The other side and the flares are left... And finished pictures in the sunlight all nice and clean!

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More to come...

Cheers for now!!

EDIT:: I got the other side done and it seems like they assemble these back to front... It was best to install the rear fender, then the running board, then the front fender... I didn't tighten anything until it was all lined up...

Another thing some of yous might find interesting... I got the flares off my old rear fender parts... The clips aren't too bad to remove... The interesting part is that the slots in the rears for the flares seem like they are done quickly at the dealer by the lucky guy that got the job... Both sides look........ Well, I think my son could have done a better job... I'm going to spend a little more time on making the slots than the other tech did...

Pictures tomorrow...

Cheers!!

Good day all!!!

Well, I didn't get the X washed, but I did dig into my LCM issue... So, the PO told me that the sunroof drain was clogged and the water ran down onto the LCM and shorted it out... And fixed the drain... But, from the day I got it, the status was not showing up on the dash... No turn signal status/noise or high beam indicator... I really enjoyed not having the clicking from the turn signals, but did want the indicator flash... And the high beam indicator is really needed!! I got an LCM from a 540i out of the PIY the other day... All the ones from the X5's were gone... The part numbers for the X5 and 540i were the same, so I gave it a shot... I pulled out the old one and immediately figured out why the one in the X wasn't working... Corroded and broken wires and broken pins... A little solder and cleaning did wonders... If it wasn't for the broken pins, I would have put the original one back in... But, the 540i version worked more or less...

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Crazy corroded!!

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This wire is broken... I had to pull the connector apart (already apart here) and pull the pin from the connector... Spot #36... soldered the wire right to the end of the connector and so far so good... If this didn't work, I would just get the length of wire with pin from the donor car and solder into the existing wire...

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Very corroded again!!!

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Original module...

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There are two pins missing from the module... Only one was still in the connector that I got out... The other was totally gone...

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Last connector in okay condition...

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Program went okay, but I can't use my fog lights for some reason... Might be a pin issue... or what have ya... The button turns them on, but they don't stay on... All dash indicators work... Unfortunately, I can't code the turn signal clicking off... WinKPS can't see the LCM for some reason... Something for another time... It works, more or less again...

Cheers for now all!!!

Good day all!!!

It has bee some time since I posted on here... I should include a lot of the recent events... I've been pretty busy with the 6MT conversion... I think this beast is next up for the conversion... I'll start a new thread on that since the (BLEEP BLEEP BLEEP BLEEP) at photobucket killed all my pictures on all my posts...

The most recent event was the rear pass window regulator failure... If you don't have a spare, I recommend getting one... I had to reassemble mine to keep the window up until I can get the replacement regulator... What a mess that was... And the clip that holds the rear quarter window assembly on is insanely resilient!!

Okay... That's it for now... Stay tuned for the new thread on this saga!!

Cheers!!!