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Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E39 (1997 - 2003)

E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 07-28-2014, 10:55 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Location: Caboolture Australia.
 
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Mein Auto: E39 535/6
Well I'm doing it...

I've just bought a 6 speed conversion kit from California. http://www.ebay.com.au/itm/181439926817
It's at O.C. Crating now getting prepped for shipping. I hope to have it in about 40 days.
While it's getting here I'll be putting the car up on the stands and getting the dead auto out and the rest of the bits, pedal sets, making preparation to put the hard lines in and making the wiring mods.
With any luck it's just bolting it all in, hooking up the laptop to do the coding and all will be good.
I had to check to see if they did in fact bring out a manual version of the 535, to which they didn't have any 535's in the USA, none of the V8 E39's came out as a manual here in Australia but they did have a 5 speed E39 535 in Europe, so I'm in luck that the manual coding exists for this model.
Fingers crossed it goes according to plan. I'll be the owner of something pretty unique once it's finished.
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  #2  
Old 07-28-2014, 10:59 PM
edjack edjack is offline
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Good Luck. It has been done, but the programming is not trivial.

I've heard this before that the V8 6-speed was not offered Down Under. Any idea why?
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  #3  
Old 07-28-2014, 11:05 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Mein Auto: E39 535/6
My guess was that marketing folk decided that more people would opt for the M5 if they didn't have the V8 as a manual...
They might have viewed the 540/6 as taking potential M5 clients away so they applied the same logic to the 535i as well.
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  #4  
Old 07-29-2014, 07:02 AM
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sixpot_simon sixpot_simon is offline
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Mein Auto: E30, E39
It wasn't just the V8s, all non-M5 E39s were auto only in Australia. Maybe the dealers found the manual E34s hard to shift or something.

Looks like you'll have the 2nd 535i/6 in the country! http://www.carsales.com.au/private/d.../?Cr=1&sdmvc=1 (maybe this guy has some tips to share on the conversion)

All the best for the project.
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  #5  
Old 07-29-2014, 03:29 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Location: Caboolture Australia.
 
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I'm pretty sure I've seen E39 I6 ones in manual here. I'll shoot that guy an email asking advice as well.

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  #6  
Old 07-29-2014, 03:56 PM
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sixpot_simon sixpot_simon is offline
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That's because there's a couple of private imports floating around (including mine!)

Hope the conversion goes well.

Simon

Last edited by sixpot_simon; 07-29-2014 at 07:06 PM.
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  #7  
Old 07-29-2014, 05:50 PM
StRaNgEdAyS StRaNgEdAyS is offline
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The guy replied... he got a specialist to do the wiring and coding, though he did confirm the whole lot just bolts in easily.
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  #8  
Old 06-20-2015, 12:01 AM
StRaNgEdAyS StRaNgEdAyS is offline
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Well I guess I better update my progress.
I'm in no hurry, luckily.
The conversion kit came, a couple of bits missing, no shifter support bush, and no shifter boot or knob. The pedals posed a bit of a challenge, but eventually I just ordered a new brake and clutch lever from the UK to swap out the ones on my US cluster and I'll use the accelerator lever from my existing auto RHD pedal cluster.
It would be so much nicer to do on a hoist. Click image for larger version

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  #9  
Old 07-15-2015, 08:34 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Mein Auto: E39 535/6
Pedals ready to go back
I used my existing RHD bracket with its throttle lever, the clutch switch and over centre spring/plunger from the LHD pedal set with a pair of levers bought from the UK.
The hard line and the loom adapter for the switch on the clutch master cylinder are coming from Germany via BMW Australia. The parts guy was rather eager to help me with this project.
A new rear main seal is on the engine and a new front seal is in the transmission. Click image for larger version

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Did I say this would be so much nicer to do on a hoist?
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Last edited by StRaNgEdAyS; 07-15-2015 at 08:38 PM.
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  #10  
Old 08-02-2015, 08:21 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Mein Auto: E39 535/6
Clutch line arrived at BMW.. Was delivered on Friday.
I was expecting something larger... The part listed on RealOEM appeared to be from the master to the slave cylinder flexible coupling. This appears to be from the master cylinder to just out of the pass through in the tunnel. Click image for larger version

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Old 08-02-2015, 08:28 PM
StRaNgEdAyS StRaNgEdAyS is offline
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I want to start the wiring changes, but this particular bolt, I can feel it's nut clicking around. I'm not sure how I'm going to access this without having to replace the housing. This I feel is one of those 'sucks to be you' moments... Click image for larger version

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Old 08-02-2015, 11:43 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Actually... 2/4 of them have the captive nut rotating in the plastic base.. I may have to drill the heads off and remove the entire unit to repair it. Yep... It sucks to be me lol
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  #13  
Old 08-03-2015, 11:51 AM
plmadding01e39 plmadding01e39 is offline
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Mein Auto: 2001 BMW 540i/6
You are making progress! You are more ambitious than I.
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  #14  
Old 08-03-2015, 01:13 PM
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DHoang DHoang is offline
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THX for posting pics. Gives us some hope that we could someday tackle projects like this.
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  #15  
Old 08-03-2015, 02:56 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Quote:
Originally Posted by DHoang View Post
THX for posting pics. Gives us some hope that we could someday tackle projects like this.
That's all good. Pictures are to illustrate all my mistakes so you don't have to make them too lol.
Other pics here..
This is the knock out for the clutch fluid line from the reservoir.. The grommet just arrived today for me to install this line, so this is today's job while I think on how I'm going to attack those two cover bolts...
I expected it to be a round hole, but after seeing the angle the hose comes through I understand why an elongated hole like this is preferable. The second pic shows the tap point from the fluid reservoir, the end is simply clipped off to allow fluid to pass.
I might add, this is a RHD vehicle, so things are mirrored compared to most others. Click image for larger version

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Last edited by StRaNgEdAyS; 08-03-2015 at 02:58 PM.
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Old 08-03-2015, 09:53 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Mein Auto: E39 535/6
The wheels have arrived
Genuine BMW two piece 18" cross spoke staggers.
No centre caps though, I'm guessing this is a 68mm centre cap required... Back to eBay it is lol. Click image for larger version

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Old 08-05-2015, 06:53 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Knock out removed (amazing how easily they come out with a small tap) and pedal set installed. The line that came with the original parts order is not quite long enough to reach... Guess that's easy enough to remedy though... If only all the problems were this easy to deal with.
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Old 08-05-2015, 06:59 PM
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16valex 16valex is offline
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Those style 42 and tires must have cost you a fortune.
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Old 08-05-2015, 07:02 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Would you believe $1350?
I watched them go around twice on eBay before I decided to bid the third time around.. I did it in the last minute too at the $1200 opening price only to be outbid almost immediately lol.. I still won in the last second lol.
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Old 08-05-2015, 07:10 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Spaghetti anyone?
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Old 08-05-2015, 07:18 PM
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16valex 16valex is offline
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Quote:
Originally Posted by StRaNgEdAyS View Post
Would you believe $1350?
I watched them go around twice on eBay before I decided to bid the third time around.. I did it in the last minute too at the $1200 opening price only to be outbid almost immediately lol.. I still won in the last second lol.
That's actually very good deal consider how rare the 18"s are and with good tires I hope.
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  #22  
Old 08-05-2015, 07:28 PM
StRaNgEdAyS StRaNgEdAyS is offline
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Location: Caboolture Australia.
 
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Fronts are nearly new, rears have camber wear.
Speaking of which..
I may well drive it down to the GoodYear store I used to work at once I'm done and pay my old boss an extra $100 to let me do the alignment myself.
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Old 08-05-2015, 07:40 PM
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16valex 16valex is offline
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Quote:
Originally Posted by StRaNgEdAyS View Post
Fronts are nearly new, rears have camber wear.
Speaking of which..
I may well drive it down to the GoodYear store I used to work at once I'm done and pay my old boss an extra $100 to let me do the alignment myself.
Good deal! I removed all negative camber on mine. Hate to go through tires like it's no one's business..
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Old 08-05-2015, 09:20 PM
StRaNgEdAyS StRaNgEdAyS is offline
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I am pleased to say I now have the correct number of pedals... Click image for larger version

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Old 08-05-2015, 10:23 PM
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Quote:
Originally Posted by StRaNgEdAyS View Post
The wheels have arrived
Genuine BMW two piece 18" cross spoke staggers.
No centre caps though, I'm guessing this is a 68mm centre cap required... Back to eBay it is lol. Attachment 523084
Wheels look awesome, I want to see those on the car!
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