01' 3.0i X5 Automatic to Manual Transmission Conversion
 

Well the time has come to make a transmission decision. My torque converter has been on its way out for the last 2 months and now if Im on the freeway for longer than 10 miles my Transfailsafe light comes on and tells me the torque converter is excessively slipping. Luckily I live 1 mile from work so it rarely goes on the freeway but Im sick of planning my trips with my other vehicle. The X5 is too comfy and perfect for road trips to not be utilizing right now!!!!!!! :nanana:

I have thought about just doing a torque converter and it will probably fine and good to go for quite some time but then it the whole transmission could fail any day at 223,000 miles. Which means doing about 10-15 hours of frustrating work could be a big waste soon after.

I have also thought about buying a low mileaged transmission putting a new torque converter in that and probably being good to go except I hate driving an automatic and would rather shift gears ( more fun to drive and nothing to worry about maintenance wise other than a clutch)

My questions to you the X5 gurus is

Are there any differences in transfer cases between the Manual and the Automatic?

Is the driveshaft a different length since its a completely different transmission?

I already realize I will have to recode the computer, install the pedal, master cylinder etc. Which will be a pain in the a$$ but worth it once its done to me.

Luckily I can do all the work myself so I wont have to pay the Indy or Dealer to do anything just the parts and my labor.

Can anyone think of any other forseen problems other than what is listed.

Thanks for your insight and help!

Some differences with the radiator/expansion tank due to the plumbing for the heat exchanger.

Transfer case has a different part number. Not sure what the differences are, could be the mounting flange, or could be internal.

Differentials are different. Not sure if the ratios are different for the manual, or if it is just something minor.

Driveshafts show as the same.

Only way to do it that isn't cost-prohibitive is to find a wrecked manual transmission vehicle and swap the parts over, IMO.

Ya Im planning on spending $1500 to do the swap which I think is enough money to handle everything. I will figure out what my differential ratio is by looking at my original window sticker if its on there. I think its a 4:10 which would either need to be changed or maybe a different manual transmission would have to be used with a longer OD gear. The E46 M3 6 speed will bolt up to this motor but Im not sure how the gearing is set in those transmissions.

My '01 3.0 5 Spd manual has that 4.10 rear end...rpms are high at highway speed. I don't recall the rear axle ratio for the newer MY 6 spds, but I think it remained that 4.10, though not sure. I could look it up...

Fwiw, I would chase a 6 spd X5 trans as it has a slightly OD driven 6th. Though 6 spd manuals were only for a few years, and manual X5s are rare.
Not sure on the M3 box ratios either.

Your idea has come up on the ol' JukeBox here, a few times, though I don't recall anyone actually having done the conversion.
GL, mD

Did they make 6 speed 3.0's????? I thought that was just the 4.4's.
I'll look into the E46 M3 Transmission ratio's to see what 6th is compared to the factory 5th Gear in the X5.

They never made a manual available for the 4.4, only the 3.0, in X5s.

The 6 spd manual was offered 2003? through 2006 MY.
GL, mD

6 speed manual was from 2004 onwards, with the LCI.

Both the manual and automatic show as using 4.1 diffs, but those diffs still have different part numbers for manual vs automatic.

I think it is unlikely that the M3 transmission would match up to the transfer case. With the automatics, a different version of the automatic is used from the rwd models just to match the transfer case, so I would suspect the same. May not just be the tailshaft housing, but also the output shaft.

Something I've been wondering is whether an e46 xi tranny would work for an X5. Realoem lists different part numbers, but this may be due to gearing since the e53 has a "stump puller" first gear. The e46 trannys can be found for a few hundred dollars...

A few hundred bucks? Where?

Just a wild idea, but how about a 6 spd out of a wrecked 5 series...seems like that might be a more logical/doable fit. Or, keep looking for a 6spd out of a wrecked/junkyard '04+ X5.
GL,mD