Auto to Manual tranny swap instructional (Preface)

[xLibelle]

So, as some of you know, i have begun the change. Kinda exciting.
Little bit of a problem, i live in memphis and my car and shop is in Savannah GA (home). So planning is key on saving travel costs and a lot of time.

First part of the game, is gathering all the parts. Best thing is to find a "donor" car at a "pull-a-part" junk yard so you actually have everything in sight and in the mean time, learn how to take it appart/put it together. Thats the second problem on my list - memphis sucks for junkers and any 325's with anything good left over. And im not in Atl long enough to get the parts out. So Ebay was the way i found much of my stuff. And even through a couple of transactions, i got scammed. Either way, finding parts can be the worst part of the entire process!!!!!

Pricing: $250 for tranny, $250 for majority reconditioned drive line parts, $240 for Bav auto clutch rebuild kit. so im still missing the flywheel (can be obtained real cheap and then machined) and the cheap odds and ends parts. Labor... free.

So the first weekend was to take things appart and access the damage of missing parts. Well, i didnt get to taking things appart on my car, but another, which helped me see issues that might arrise - including a sequence of events for installation. Which is rare to nill to find on the net - another reason i am posting this instructional.

I will post a full parts list required for the swap and some extra bits when i have another moment in the next few days.



auto automatic manual standard tranny transmission swap change 325i 325e

 

[jonnyz16]

Sounds great man ..good luck . I think it's awesome that you're going to take time and put together a detailed instruction procedure. right on . You'll love a 5 speed in your ride. I'm thinking about doing an install faq when my chip and exhaust get in, but I haven't said to much about it incase I puss out..

dont forget to take some degreaser and penetrating oil for the dirty and sticky bolts when picking-your-part..

 

[Auslander RML]

Wow...sounds like a pretty big endeavor, especially while documenting the process for others to reference. Major props!!

 

[Piluso1]

I'm in the procces of buying a 325i 1990 that has an automatic on it, really cheap because it needs a head gasket and was thinking about the conversion to 5 speed, my problem would lie on the pedals and how to change them....keep posting and if I go through with the purchase might be able to help you with a few things....

 

[xLibelle]

...three weeks later*

i got back down to the car with the last of the parts and a game plan (which happened to be, just do it already) - i guess first thing that is in order is a parts list.

1. tranny input shaft support bearing
2. flywheel (i)
3. clutch disk
4. pressure plate (i)
5. bolts - pressure plate to flywheel (x6)
6. release bearing
7. release lever
8. pivot pin and retaining clip for release lever
9. Getrag 260 transmission (specifically for 325i e30)
10. transmission support bar with mounts
11. driveshaft (for standard drive)

12. brake fluid resivoir with clutch supply port
13. fluid supply line from reservoir to master cylinder
14. master cylinder
15. clutch and brake pedals (ii)
16. hydraulic line from master to slave cylinder
17. slave cylinder

18. shifter (shift knob, upper lever, lower lever and junk in between)
19. rubber boot with backup-light switch
20. ball cup
21. shifter console/carrier (aluminum rod recommended)
22. rear carrier mount bracket and bushing
23. shift rod
24. front carrier bushing, shifter bushing, circlip, mounting clip, etc.

The list pretty much covers every part needed to get a working system going. there are minor nuts and bolts that can be dug up around a shop or from the hardware store... there might be a few bolts that get rounded (exhaust nuts and tranny mount bolts) that may hinder the build process.

Unless the tranny is newly rebuilt, i recommend the bavarian auto clutch kit including 1, 3, 4, 6, shaft seals, rear gasket, and exhaust gaskets. (i)

pricing is pretty much covered in the first post pretty well and all depends on where and how you obtain the parts. i suppose i went about gathering parts pretty well.... for a noob.

(i) - when picking out parts for rebuild, you might as well go all the way so you dont have to repeat the process... maybe! Specifically, lightened flywheel and performance pressure plate: if you do NOT plan to heavily mod and race the car, dont bother. It will be more of a hinderance than performance gain. The stock PP is rated for a 200hp engine, plenty grip for what we have and the FW could lose some extra weight (not a lot) but isnt worth it. Not to mention it can get hot faster and wear the disk quicker.

(ii) - depending on the age of the car, there are two different kinds of brake/clutch peddal assemblies. Older model (pre 89(?)) has an assembly that can be removed in its entirety - easily. So the standard and auto assembly can be swapped. IF the auto already has the spring guide for the clutch, then all you need is the peddals and axle with bushings.
As you can see here:

Auto missing the spring guide:

In the newer models (last few years) the assembly will be welded into the car as part of the steering column! As you can see here behind the brake sensor wires - it is supposed to have bolts where the hole is, but instead welded to the column.

The big issue here is the spring guide. So i constructed a bracket that is just bolted on where you bolt the master cylinder to. I made a few extra just in case anyone finds they need this, it is a very easy fix.

I will update the list as i finish the swap and find out if a couple parts can just be used from the auto setup.

 

[xLibelle]

Tools eh? Used my fingers for everything .... sike.
One thing ive learned, extentions are your best friend. I needed a total of three feet in extentions. Plus that because i snapped a couple half inch ones too. Let me just run down the list.
crescent wrenches and sockets at sizes: 10 to 22 mm to name the bare minimum. Might as well have a standard set around as well, we used them at a couple places.
breaker bar - at least 1' long
Torx sockets 8, 10, and 12 mm sizes
Phillips and flat head screwdrivers
There wasnt much variation on the tools we needed. Extra stuff was good to have like hammer, air ratchet, car jack, ...kitty litter, dirty language.... that about covers it

Ok, enough with the small talk - click this to get the show on the road: Auto to Manual tranny swap instructional (How To)