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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 04-17-2013, 08:10 PM
5series92 5series92 is offline
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Auto to manual 6 speed conversion parts list

Hello all. I have decided to convert my 97 540ia to a manual 6 speed gearbox, looking around online I have found discussions but none on the e39 540i I'm just looking for a list of all the parts I would need for this.

So if you have gone through this or have an idea of what parts I need besides the tranny, flywheel, clutch and drive shaft please feel free to comment. Thanks in advance
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  #2  
Old 04-17-2013, 08:25 PM
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hh3uunp hh3uunp is offline
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Quote:
Originally Posted by 5series92 View Post
Hello all. I have decided to convert my 97 540ia to a manual 6 speed gearbox, looking around online I have found discussions but none on the e39 540i I'm just looking for a list of all the parts I would need for this.

So if you have gone through this or have an idea of what parts I need besides the tranny, flywheel, clutch and drive shaft please feel free to comment. Thanks in advance
Not much off the top of my head

Driveshaft
pedals
cruise control switch
BMW INPA, NCS Expert
transmission and linkage
clutch hydraulics (slave cylinder, master cylinder, hoses)
rear main seal
flywheel
clutch you should replace anyways

Its not too bad if you have a parts car at like a junkyard it can be done cheaply
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  #3  
Old 04-17-2013, 08:36 PM
5series92 5series92 is offline
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Quote:
Originally Posted by hh3uunp View Post
Not much off the top of my head

Driveshaft
pedals
cruise control switch
BMW INPA, NCS Expert
transmission and linkage
clutch hydraulics (slave cylinder, master cylinder, hoses)
rear main seal
flywheel
clutch you should replace anyways

Its not too bad if you have a parts car at like a junkyard it can be done cheaply
I found a totaled donor car on Craigslist I just don't know what parts to pulls off it.
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  #4  
Old 04-17-2013, 11:36 PM
Mysemannen Mysemannen is offline
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I would also try to salvage the manual engine harness as it differs from the auto one regarding reverse signal.
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  #5  
Old 04-18-2013, 05:57 PM
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hh3uunp hh3uunp is offline
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I don't want to disagree because I have never done a complete swap but wouldn't it be a lot more easy just to modify the existing harness. When I see all those wires I would faint
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  #6  
Old 04-18-2013, 07:29 PM
e39 crackr e39 crackr is offline
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I will be doing my swap Memorial day weekend.

Here's a couple of links to help you out:
http://forums.bimmerforums.com/forum...ght=faq%206spd
http://forums.bimmerforums.com/forum...light=swap%206
http://forums.bimmerforums.com/forum...ed-Swap-Thread
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  #7  
Old 04-18-2013, 09:03 PM
5series92 5series92 is offline
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Originally Posted by e39 crackr View Post
How long do you think the whole process is going to take?
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  #8  
Old 04-18-2013, 10:20 PM
Mysemannen Mysemannen is offline
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Quote:
Originally Posted by hh3uunp View Post
I don't want to disagree because I have never done a complete swap but wouldn't it be a lot more easy just to modify the existing harness. When I see all those wires I would faint
Indeed, use the salvaged one to compare
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  #9  
Old 04-19-2013, 03:30 AM
e39 crackr e39 crackr is offline
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Quote:
Originally Posted by 5series92 View Post
How long do you think the whole process is going to take?
With the right tools and people to help, should take 2-3 days at most.
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  #10  
Old 04-19-2013, 07:49 AM
5series92 5series92 is offline
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Originally Posted by e39 crackr View Post
With the right tools and people to help, should take 2-3 days at most.
The reprogramming seems to be the most challenging part. I spoke with a BMW indie specialist, he said the ecu always has some bugs and little issues after the reprogram
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  #11  
Old 04-19-2013, 11:04 AM
HTK12 HTK12 is offline
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Quote:
Originally Posted by 5series92 View Post
The reprogramming seems to be the most challenging part. I spoke with a BMW indie specialist, he said the ecu always has some bugs and little issues after the reprogram
I would say the easiest part is the programming. Retrofitting parts and wiring will be the most challenging. That is, if one knows how to program. It really isin't too challenging to program once you get the hang of it. So learn how to do it yourself or take it to someone how does BMW programming regularly. Your local BMW specialist probably has no clue to what they would need to do. When they swap modules they use tools like Autologic, Progman, DIS etc. where you only need to press few buttons to program a new module or retrofit equipment. When your doing something like this you need to tools like NCS Expert. The difference is that NCS Expert won't give you any guidance like Autologic, Progman, DIS etc. will. The upside is when you know what you want to do in NCS Expert you can do it pretty damn fast.
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  #12  
Old 04-22-2013, 12:57 PM
Reefin' Dude Reefin' Dude is offline
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i am also thinking of doing this swap, though on a touring. maybe the touring is different, but why do you need to swap out the drive shaft? the part numbers are the same. wouldn't the part numbers be different if the lengths were different?

G~
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  #13  
Old 04-22-2013, 01:41 PM
5series92 5series92 is offline
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Originally Posted by Reefin' Dude View Post
i am also thinking of doing this swap, though on a touring. maybe the touring is different, but why do you need to swap out the drive shaft? the part numbers are the same. wouldn't the part numbers be different if the lengths were different?

G~
Because the drive shafts have different lengths, i think the manual is a bit longer than an auto
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  #14  
Old 04-22-2013, 01:50 PM
Reefin' Dude Reefin' Dude is offline
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i did some more searching, the part numbers are different. they do seem to be the same drive shafts for both sedan and touring. i must have looked them up improperly the last time i did this in RealOEM. sorry for the confusion.

G~
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  #15  
Old 04-22-2013, 01:52 PM
HTK12 HTK12 is offline
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Late reply

Last edited by HTK12; 04-22-2013 at 01:53 PM.
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  #16  
Old 06-17-2013, 05:23 PM
tt_tony tt_tony is offline
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I have two questions:

Is it possible to swap a 5 speed from a 2000 528i into a 2003 530i?

-and-

Since I/we have access to donor cars and relatively cheap parts, why don't I/we just change ALL the necessary modules and electronics instead of worrying about programming and incessant "bugs"?

Thanks,

tony
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  #17  
Old 06-18-2013, 02:36 AM
Burning2nd Burning2nd is offline
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she'll never run again!

cluster
steering wheel
slave cylinder line and master
gibo, drive shaft houseing
drive shaft
trans and mounts

+ all thee electrical problems..... (this is why she'll never run again)
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  #18  
Old 06-18-2013, 03:53 AM
e39 crackr e39 crackr is offline
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Quote:
Originally Posted by Burning2nd View Post
she'll never run again!

cluster
steering wheel
slave cylinder line and master
gibo, drive shaft houseing
drive shaft
trans and mounts

+ all thee electrical problems..... (this is why she'll never run again)
Sounds like you have not found the right shop to do the reprogramming. Mine came out just fine, took 5 flashes but it's all good!
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  #19  
Old 06-18-2013, 05:20 AM
tt_tony tt_tony is offline
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ha, first of all, what is a gibo? (gearbox maybe?)

second, all the parts you mentioned are easily changed so, again, why can't I just swap out the electronics as well?

Even if every module in the vehicle is tied together through bus comm, why can't I just swap them all?

thanks
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  #20  
Old 06-18-2013, 05:40 AM
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doru doru is offline
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A bit late, but I pdf'd the xls sheet for a manual conversion. The list is for a e46, but having the p/n you can easily cross-check for the e39 p/n

ManualConversionPartsList.pdf
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  #21  
Old 06-18-2013, 05:54 AM
tt_tony tt_tony is offline
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that's great. thanks for that. so that "total price", did you have a donor car?
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  #22  
Old 06-18-2013, 06:23 AM
Burning2nd Burning2nd is offline
Under the lift arms
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Lol ok ok,,,, were talking swaps but we don't know what the Gibo is ??? Lol come on
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Old 06-18-2013, 06:25 AM
Burning2nd Burning2nd is offline
Under the lift arms
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Quote:
Originally Posted by tt_tony View Post
ha, first of all, what is a gibo? (gearbox maybe?)

second, all the parts you mentioned are easily changed so, again, why can't I just swap out the electronics as well?

Even if every module in the vehicle is tied together through bus comm, why can't I just swap them all?

thanks
Show me the money mr ez swap, you swap it and get it running right and then come back and say how great of a swap it was ...
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  #24  
Old 06-18-2013, 07:55 AM
tt_tony tt_tony is offline
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i said the parts are easily swapped. I didn't say it would be easy to get it running. that's what i'm asking about!

btw, i've been working on cars a long time (relatively new to bmw's, i'll admit) and ive never heard anyone heard it called a "gibo". weirdos.
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  #25  
Old 06-18-2013, 09:44 AM
Burning2nd Burning2nd is offline
Under the lift arms
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Gibo is the flex disk between the trans out put and the front of the drive shaft


I've also been working as a mechanic my hole life , granted I now do industrial maintance (better $)
Bimmers are no different , if your set in a swap first thing u need is all your electrical diagrams your gonna need the Bentley manual


Honestly it's not worth it , sell it and buy a new one
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