auto to manual conversion/swap FAQ

[garyinwestoz]

Despite my woeful searching attempts, whereby nothing came up and referring to my previous thread back in 2016 , http://firstfives.org/phpBB-3.2.1/phpBB ... f=4&t=5060

I request a Manual Conversion FAQ be made

why
cause Im doing one myself and want to sort out all the parts from the donor car before hand.

so far list is ( Right Hand Drive)

interior

• - manual instrument cover ( ie plastic which covers the PPRND12 slots which light up)
  • - gear shift and knob, gearshift gattor/cover, centre console tray with gear lever cover + fixing screws
  • - speedo drive + speedo cable ( lower section to centre vent and upper section to instrument panel) (LHD may be different)
  • - manual pedal assembly ( including gasket to firewall), brake and Clutch, pedal rubber pads, stop light switch and all bolts/screws/nuts
  • - clutch master cylinder, pipe to clutch slave cylinder ( mounts to firewall) with pipe fixings brackets to firewall+ screws, clutch slave cylinder
  • under dash cover - (has cutout for clutch pedal)

engine bay + below
-

• 5 speed Getrag 265 O/D transmission with gearshift mounting bracket + 4 x new mounting blocks , clutch plate, a new clutch release bearing , clutch lever and new pivot ball, bellhousing + bolts to suit M30 engine (2.8, 3.5), flywheel with bolts
  • - new drive shaft pilot bearing , new manual guibo coupler, coupler cover, new coupler bolts and nuts, drive shaft with centre bearing+ protection plate, full length to rear diff including all bolts+ nuts
  • - trans support crossmember, bolts and rubber support
  • - reverse light switch and cable that runs up and through fire wall , conects to connector then connects to …? - all that as well
  • - brake master cylinder fluid reservoire + pipe to clutch master cylinder
  - general clean to all the above
  - allparts labelled ( small parts bagged in zip locks)

new parts to get ( to replace likely worn out parts)

• -pilot bearing
  -guibo
  -shifter mount blocks - 4 of
  -shifter nylon shims
  -clutch cylinder seals
  -slave cylinder seals
  -clutch release bearing
  -clutch plate
  -clutch lever nylon pivot thingy
  -master cylinder reservoir

other things to adjust
disable no start switch in auto shifter

[garyinwestoz]

further to the above

reverse light switch and cabling

on my manual car - the cable for reverse light switch ( for RHD) goes from the trans, upto the firewall, then through it to a junction/connector just on the other side of the firewall. Where does the cabling go to from there?


my auto seems to have the same internal cabling ( no external cabling) - so I hope this is a direct plug and play scenario
but once the auto cabling is unpluged - what stops working?

cable on engine side going through fire wall

IMG_3691 by g dornbmw, on Flickr

connector on interior side of firewall - auto has a similar connector with something plugged into it!

IMG_3694 by g dornbmw, on Flickr

another view of that connector

IMG_3692 by g dornbmw, on Flickr

[garyinwestoz]

found a few threads

http://firstfives.org/phpBB-3.2.1/phpBB ... f=4&t=3777time it takes + partial parts list

http://firstfives.org/phpBB-3.2.1/phpBB ... f=4&t=2985 wiring

http://firstfives.org/phpBB-3.2.1/phpBB ... f=4&t=2401 blaise wiring, bypass relay

http://firstfives.org/phpBB-3.2.1/phpBB ... f=4&t=3873 crossmember

http://www.firstfives.org/fspeed.html 5 speed conversion from old board

e24 conversion bimmerboard parts list
http://www.bimmerboard.com/forums/posts/1059991

[Lock]

I did this a couple of years ago, take a look
http://firstfives.org/phpBB-3.2.1/phpBB ... php?t=5359
I used a 260, not 265, but the idea is the same. You don't need a new under-dash cover, you can just carefully cut out the clutch pedal gap.
Pretty sure the revese light cable goes into the firewall, into the harness behind the gauge cluster, then that runs down along the sill by the driver door to under the rear seat, then out to the trunk to the reverse lights.
I hooked up the reverse light wire and ignored everything else, then under the dash removed and bypassed the inhibitor (P-N starter) relay as it's no longer required.