Project twin e34's + X5 4.6is manual swap

[Michael. 2313]

E34s with new suspension front to rear, would be very neat indeed. They all need it now. 

[e46v12 477]

So the end of a chapter with my 1st e34 as she has been officially sold tonight. Sad to see it go but glad someone else can appreciate her. Advertised  for 1day on trade me and shes been snatch up.

Maybe the new buyer is a member of the group too?

Sorry for all the photo's its more for memories for me  

 

 

 

 

Edited March 5, 2020 by e46v12

[zero 1162]

Was this the one from Auckland?

[e46v12 477]

Hey Nathan

No that one was parted out straight away, i took the running gear and sold on the rolling body due to the amount of rust. This is my original build from the very start along with the 540i wagon. 

Hows your wagon coming along?

[zero 1162]

I'm in talks with a few people overseas about a 4.6 engine so hopefully I can land one soon.

Ive been working on the dry sump setup in the meantime

[e46v12 477]

oh Nice be good to see some updates on your build too.

[e46v12 477]

Hey Team 

Its been a while but finally getting onto this X5 manual swap with all this time on my hands.

So Im slowly starting to dismantle the motor in order to change all the gaskets, seals and timing guides. Ill order them once the lock down is over. 

But manged to get the manual box up into place to see how i was going to attack the gearbox mount and driveshaft.

But managed to almost solve the driveshaft issue. Reusing the rear half off the x5 then i found an old e34 525i front half that u joint splines matched but the input part was too small and just short maybe 15-20mm in length. So im going get input part off the driveshaft that came with the box with the extra 20mm and get it welded onto the 525i shaft to match the 420g box and Guibo, that will solve that problem.

top shaft off a e39 540i

middle x5

bottom e34 525i

 

 

 

 

 

 

 

Edited April 9, 2020 by e46v12

[e46v12 477]

Hey Team

hope you all had a nice Anzac day of remembrance.

So keeping busy in lockdown and trying to make the most of this free time.

I had a pre 98 e39 pedal box that i thought the pedals would work as the part numbers match but for some reason it wouldnt work with the x5 Brake bracket. So with some left over bits from a e87 pedal box i manage to make something that will hopefully work. Cutting the x5 brake pedal down with a cardbourd template.

Just a rough test fit to check if the clutch pedal clears the foot rest and luckly it does as the e87 pedal hangs to the left as you can see.

Brought another Solid Mount Shifter from BM speed shop ( trying to support local businesses) for an e46 and mounting point work,  Just need to lengthen the e39 selector rod.

Pulled the motor out and stripped it to change all the gaskets and timing chain guides but looks like they were already done as they looked brand new.

these are the bits of the old timing Guide after removing the upper oil pan.

Gave the block and all mating surfaces a good clean too, took the outer c.v joint off the shaft to be reused and repainted the valve cover.

and saw this too that the block had a b44 stamp on it.  BMW must have just reused the 4.4 blocks and bored them out a few mm.

Also thought id give this a try, placed a whole electric e46 fan and shroud inside the x5 one. Plugs are the same so hopfully can get it to work. 

So now just waiting for all the gaskets to come from FCP euro. 

 

 

Edited April 25, 2020 by e46v12

[e46v12 477]

Hey Team 

been a while since last post, so while in lockdown i got quite a bit done. 

Managed to change most of  the gasket on the motor that leaked oil, intake and few other little things. 

Motor is back in the car now, i managed to get the wiring sorted to get the car running. 

flywheel and clutch all in but yet to test.

Front half of driveshaft made and perfect fitment. 

Electric fan from e46 works a treat and cools the engine enough.

Got the Pedal box in with new rubber fed line from reservoir and new braided clutch hard line to slave cyclinder. 

Currently have a rebuilt e92 m3 diff  at Kayne Barrie's getting the flanges changed over to suit the x5 drive shafts.

So not much left to do once i get the diff back, will most likely need the rear half of the drive shaft shorten as well, move the whole car to my engineers shop. Get custom gearbox x member, length gear selector rod then ill be able to drive it.

Braided clutch line

x5 diff on the left and 330i lock diff on the right

front drive shaft taken out and just the outer cv case left in.

custom steel flywheel reusing the auto ring gear

e46 M3 centre modified to accept a nissan 250mm puck plate

Nissan pressure plate 3000lbs clamping force

All most done team.

Edited July 7, 2020 by e46v12

[e46v12 477]

Hey Team long time no post.

Well what can i say, SHE'S ALIVE

Finally got the x5 manual swap up and running, its surprisely quick too with the factory 3.91 open diff, was only sitting around 2.3k rpm at 100kmph.

Custom x member and shifter rod extended.

So just a few more tweaks, the x member needs to be raised 25mm to line up the driveshaft straighter. REst of exhaust fitted but first get the rear mufflers deleted.

I also sourced this a while ago  while discussing diff options with Kayne Barrie, I saw this on trade me and he said it could work as he had rebuilt it and knew the measurements.

a e92 m3 LSD Diff with the flanges changed out to match the x5 ones. 

I have mounted it up and almost perfect I just need to find some big washers to go in between the front two mounts

as you can see picture above,

take the drive shaft in to be shorten and it should be home sailing. I did run into some small issues with the car trying to cut out when i was over 50% open throttle at around 4k-5k rpm 

does any one have any ideas of what this could be?  i pressed the dsc button but no change. Also coded out the auto and made it manual so just a bit stumped.

Feel free to chime team.

 

 

[e46v12 477]

Hey Team

Long time no post. its been a while still the last post, almost a year. I can tell you all that the projects are still alive and kicking, I've just been busy toying with other cars, wheeling and dealing and just been a bit lazy with the posting but definitely still wrenching with the bimmers.

So another one offically done and dusted. The X5 4.6is 6 speed is finally wof, rego and certified

Had to add a couple more things to make the certifer happy. Fitted the car with some adjustables, did a rear muffle delete (myself) looks a bit horry but was free piping so I cant complain sounds bloody grunty though. I also managed to get the rev issued sorted. Thanks to DUDMD from the States. He did a remote tune to the dme by reflashing it to a e39 540i manual then reinstalling the 4.6is software. Runs a treat now with no rev hang or reving issues. 

I had to get the spring seats modified as i felt they had nothing hold them and the spring to the lower arm.

Had to get the cross member modified to have a 4 point of contact with the chassis. We added two front bits if you can see in the picture.

Had to make two driveshaft hoops too.

So also purchased this new Daily/tow car a 2006 X5 3.0d which i did an egr delete, no swirl flaps (must be because its nz new) and i got a remap done by promo. Car runs and drives awesome now. Also done some preventive jobs, waterpump, thermo, pulleys and belts, oil and gearbox fluid change.

So now just the e34 wagon left to go, I did pick up this writeoff 4.6is a while ago. I'll be using this motor and 6speed to swap into the wagon. I've already got DUDMD to send me a ews delete dme which has had the same stuff reflashed on like the X5 manual car. This will make my job a little easier gettting the car started. Fun times ahead. will keep you all posted.

Thanks Team

 

 

 

Edited August 19, 2021 by e46v12

[e46v12 477]

Hey everyone, 

So finially I got the chance to grab the e34 out of storage, been a long time coming. Spent the day just taking bits apart, took the exhaust, auto box and diff out. Will start attacking the motor tomorrow, quite tempted to just use the 4.6is motor that ive got already for the e46 project and just chuck it into the e34 as i pretty much have all parts for this project good to go.

 More to come tomorrow  

[treone 648]

My vote is to put the 4.6 into this! 😎

[e46v12 477]

@treone

I certainly am  

i have two 4.6's with one ive sort of rebuilt and ready to for my e46 and then the black X5 4.6 parts car which ive yet to pull apart and semi rebuild. The only small dilemma is if i want to use the already rebuilt one i need to take the front timing cover off and change the oil pump chain as its the wrong length for front sump oil pump type. But regardless this wagon will definitely be getting a 4.6 in it.

[treone 648]

Awesome! And manual as well? Will be watching how this build goes 😁

[e46v12 477]

@treone

yup 6 speed manual and custom exhaust headers too

[KwS 2425]

Shes a bit tight on the old hoist there 😄😄

[e46v12 477]

Hey Team

getting along quite nicely with the wagon. Managed to strip the motor and do a  self leveling suspension (sls) delete.

Hoping to start stripping the 4.6is X5 over the weekend too.

[e46v12 477]

Hey Team

So finally cracked into the X5 4.6is parts car, stripped the motor out and refurbed in the past month. Swapped the oil pump to the front sump type and replaced timing chain guides and various gaskets. Pretty much got the motor 90% ready to go back in, just need to make a custom bracket for the oil filter housing. Also arrived was my wiring harness from Condor speed which im hopping will make my job easier. But most excitingly finally got to mock up my custom exhaust headers that i had made i think a year ago, I cant wait to get this thing in the car and running.

 

Drilled out the passger side starter hole.

Fiited some 18mm frost plugs into the secondary air pump holes.

Getting closer team.

 

 

 

 

Edited October 3, 2021 by e46v12

[e46v12 477]

Hey Team

So getting a fair bit done to this build.

Cleaned the engine bay,

Fitted a custom braided clutch line,

custom clutch fluid reservoir utilising the old c101 plug holder,

manual pedal swap Lucky enough my setup had a single spring on the clutch pedal. I didnt have to go through the whole dreaded steering column removal.

retro fitted e46 drive by wire pedal,

test fitted motor with trans and custom headers to check for clearances issues,

test fitted RTD shifter from my e46 build which fits perfectly so im going to keep it for this car and shorten the selector rod too.

Started the wiring from Condor speed and it seems qute easy with good instructions. Feeding the wire throught the e-box and through a fan hole.

Little bracket made to hold oil filter housing,

New brake disc and pads to install

Will start on rear and front bushings tomorrow and send the driveshaft to get shorten.

Getting so close

 

 

 

 

 

Edited October 25, 2021 by e46v12

[Eagle 1662]

You going to put it on a dyno? Would be interesting to get an idea of how much power its putting down.

[e46v12 477]

Hi @Eagle i wasnt going to to be honest. Its completely factory other than the headers on it, it would be nice to know though. Maybe later down the track if i have funds available for it. thanks

[e46v12 477]

So managed to get the bushings and front arms swapped out on Monday. It doesnt  look like much but man it took me all day. I had one of those moments of "what a dumb arse" where the 1st rear sub frame bushing took me about 2.5 hours to do. Once i realised that i needed to leave a gap between the subframe and body of the car in order to allow the new bushing to protude through to the top. Once i clicked on that the 2nd bushing too me 15mins.I also swaped my XYZ coilovers in while i was there. Just the steering rack, tie rod ends and rear coil overs left to put in.

Edited December 1, 2021 by e46v12

[e46v12 477]

Hey team hope every one is well and ready for the silly season.

So got a few more things done to the wagon. Car is finally up and running now   though not without a few little issues. Exhaust leak, rear adjustables rebound need to be wound up to make it stiffer, wheel alignment,  smaller mid muffler to be welded in as current one is a tad low, change rear seal in the gearbox and get some tyres for the Hamman wheels.

 

Painted the exhaust and baked it in the oven.

Changed out the factory twin fuel filters and put a single one in with a regulator and ran a vaccum line up to the manifold.

Custom clutch and flywheel installed. Exactly the same setup as the manual swapped X5.

Running my spare LSD 3.15 till my LSD 3.64 gets back from Kayne Barrie getting a rebuild.

Driveshaft made to length.

Tack welded the nuts in tunnel so i could bolt down the RTD shifter without needing someone to hold the nuts for me.

Brought this ultra racing Strut brace cheap, it was made for a 525i model. I cut the bar off the hinges and flipped it, rewelded it to make it work with the 540i 

The Factory mid muffler was rusting and had a small hole, so decided to redo the whole exhaust from the new headers back. Redid the o2 sensor bungs too. But after lowering the car found the mid muffler sits too low so will change out for a smaller one.

Fitted the new Zimmermann sports brakes and pads in and flushed the brake system with new fluid.

Just arrived a couple days ago this M5 rep center console surround.

.Will be running these wheels on the car. 18 x 8.5 fronts 18 x 9.5 rears

will get a exhaust clip onces its fully running good.

Thanks Team

 

 

 

[e46v12 477]

Hey Team

happy news years to you all.

So managed to redo the exhaust to hang up abit higher under the body. Swapped the rear bumper to a m tech one, will do the front just need to get it repaired. Also scored some recaro SR7 seats currently need to sort the height on the base before i bolt them in and a sound clip of the car 

 

Thanks Team