Auto to Manual Conversion

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sideshowbob
Posts: 247
Joined: Mon Aug 01, 2011 2:18 pm
Location: Hampshire UK

Auto to Manual Conversion

Post by sideshowbob »

After much deliberation and thinking about this issue have now decided I would like to convert my '89 635 CSi Euro Highline from its present auto box to a manual transmission.
I do not have the skill, expertise call it what you want to do this work myself, so was wondering is there anyone on the Forum whi is UK based who can undertake this work.
I am not sure of all the parts that would be required and whether anyone on here as a store of 'bits' that could be used or whether you just have to search Ebay etc over a few months and pick stuff up as and when.

Any help with parts, lists of parts or the ability and where with all to do the job would be most appreciated.
ssf1342
Posts: 44
Joined: Tue May 21, 2013 1:06 am
Location: WA

Re: Auto to Manual Conversion

Post by ssf1342 »

I have been considering this swap for my '89 US spec on & off for the past few years. I've compiled an incomplete parts list that hasn't been updated in awhile, & taking into consideration that yours is a euro model, I'm not sure how much will apply but hope it will point you in the right direction. Maybe others can fill in what I am missing.

Parts List for Auto to Manual Transmission Conversion for e24
1) Boot (part #13) http://www.realoem.com/bmw/showparts.do ... g=25&fg=05
2) Center bearing (new one; part #1?) http://www.realoem.com/bmw/showparts.do ... g=26&fg=10
3) Console shifter surround
4) Clutch kit (Sachs)
5) Clutch & brake pedal assembly (parts #1-27) http://www.realoem.com/bmw/showparts.do ... g=35&fg=05
6) Clutch pedal spring compensator (from e12 or new)
7) Cross member (part #1)
a) Getrag 265/5:
b) Getrag 265/6: http://www.realoem.com/bmw/showparts.do ... g=23&fg=10
c) Getrag 260/6: http://www.realoem.com/bmw/showparts.do ... g=23&fg=10
8) Differential (with 3.73 or 3.64 LSD) from one of the following:
a) e28
b) e30 (will need to swap out differential cover)
c) e32
9) Driveshaft or propshaft (must match manual transmission you plan to use)
a) Getrag 265/5 use P/N 26111225759 http://www.realoem.com/bmw/showparts.do ... g=26&fg=05
b) Getrag 265/6 use P/N 26111225090 http://www.realoem.com/bmw/showparts.do ... g=26&fg=05
c) Getrag 260/6 use P/N 26111225461 http://www.realoem.com/bmw/showparts.do ... g=26&fg=05
i) 1566mm
10) Flex disc or guibo (new one)
11) Flywheel (single-mass; resurfaced)
12) Hoses
13) Jumper (in wiring harness where autobox gear lever used to plug in to)
14) Lines
15) Master & slave cylinder
16) Pedal box (from manual transmission car)
a) Getrag 265/5
b) Getrag 265/6 use http://www.realoem.com/bmw/showparts.do ... g=35&fg=05
c) Getrag 260/6 use http://www.realoem.com/bmw/showparts.do ... g=35&fg=05
d) Will also need new:
i) 35 41 1 113 728 - grommet x1
ii) 34 31 1 152 270 - pin x1
iii) 35 21 1 109 541 - bushing x4
iv) 35 21 1 150 346 - sleeve
v) 35 31 1 154 734 - sleeve
vi) 35 11 1 150 370 - seal
17) Pedal support bracket (specific for e24)
18) Pilot bearing or spigot bearing (new one)
19) Radiator
20) Reverse light switch
21) Rubber floor sealing boot
22) Shift linkage
23) Shift support arm
24) Shift support plate
25) Shifter assembly (rebuilt) or short shift kit (for Z3)
26) Shifter mounts
27) Supporting bracket (part #1) http://www.realoem.com/bmw/showparts.do ... g=25&fg=05
28) Transmission
a) Getrag 265/6 (part #1 or #2; must have mounting holes for Motronic sensors) http://www.realoem.com/bmw/showparts.do ... g=23&fg=15
i) Only available on:
(1) e23 Jan 1985-Sep 1985
(2) e24 US-spec Aug 1984-Sep 1985; Euro-spec 1981-1982
(3) e28 from Sep 1984-Sep 1985
ii) Getrag 260/6
(1) Only available on:
(a) e23
(b) e24
(c) e28
(d) e32
29) Transmission mounts (must match type of manual transmission you plan to use)
a) Getrag 265/5 http://www.realoem.com/bmw/showparts.do ... g=23&fg=10
b) Getrag 265/6 http://www.realoem.com/bmw/showparts.do ... g=23&fg=10
c) Getrag 260/6 http://www.realoem.com/bmw/showparts.do ... g=23&fg=10
30) Universal joint
a) Getrag 265/5 use P/N
b) Getrag 265/6 use P/N 26117511454 http://www.realoem.com/bmw/showparts.do ... g=26&fg=10
c) Getrag 260/6 use P/N 26117511454 http://www.realoem.com/bmw/showparts.do ... g=26&fg=10
31) Vibration damper
a) Getrag 265/5/use P/N
b) Getrag 265/6 use P/N 23131220589 http://www.realoem.com/bmw/showparts.do ... g=26&fg=10
c) Getrag 260/6 use P/N 23131220589 http://www.realoem.com/bmw/showparts.do ... g=26&fg=10

Supposedly there is also some kind of mounting tab or bracket somewhere along the transmission tunnel that will need to be removed from a manual transmission donor car & welded to yours if missing, but I am not entirely sure.
'03 530i auto w/sport pkg 134,369 miles
'99 740il 6-spd 223,072 miles
'90 535i 5-spd 339,399 miles
'89 635csi auto 183,xxx miles
'88 635csi auto 322,342 miles

Gone:
'85 735i auto 181,xxx (California-approved "Gross Polluter")
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