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Haven’t actually done anything to the car today, but received a pile of goodies for it. 6speed manual conversion coming up for the 540i!

As per the title, my old E39 540i is going to get the 6-speed manual conversion treatment. For me, the car is a “Sunday driver” and I just want to make it a bit more enjoyable / engaging to drive. I’m not trying to build a race / skid machine and want to keep the look and feel as factory as possible. I have the key components already, Getrag 420g gearbox, gearbox sub frame, drive shaft, pedal box, shifter linkage etc. Everything else will be replaced with new parts, clutch, flywheel, hanger bearings, master / slave cylinders, shifter linkage rebuild kit etc. Diff upgrades will come later, probably much later as the “toy account” has taken a hammering with this project so far😭 Keen to hear opinions on clutch / flywheel combos, and where to purchase parts from. I’m 95% certain I will go with a dual mass F/W to keep the factory feel, unless someone can convince me otherwise? I have a “wish List” of parts on ECS Tuning’s website, but would prefer to purchase locally if it stacks up, so open to suggestions on local parts suppliers too. I’m not in a hurry to get this done and want to make sure I have what I need before starting the job, but planning to have it done and ready for next summer😎 The mechanical side of the conversion I think I will manage ok (have done this myself successfully on my previous E36 328i) but I believe there is a bit more work on the DME / programming / electrical side with the E39, so I will be reaching out for some help in the future around this😵 There will also be a good 540 / M62 auto trans coming out if anyone needs one, happy for test drive if your interested. Please chime in if you have useful advice info etc. Will keep this updated as I make decisions, collect parts and begin the conversion, plus include plenty of Pic’s where needed.

Exhaust manifold flange gaskets. All the shifter bushings if they havent been done. Maybe engine\transmission mounts, rear main seal, slave cylinder, flex disc and center bearing depending on their condition\wear.

The one on the left is prone to breaking down and giving endless trouble. The one on the right is a bit over powered for everyday use, but will make it more fun.

Still have the M325i ! Will definitely be taking this out in the near future 😃 Didn’t have much luck selling a little while back but open to moving it on if anyone is serious.

... Or is it being moved on 👀

Probably a high ranking Mason.

check the impact speed sensor for water damage corrsion ,under the left seat under the carpet