Double DIY: Auto to Manual Conversion

[stig]

DIY 1: I'm in the process of piecing together a complete manual transmission set. One piece led to another, and before you know it you can't stop. As of today (07-08-2011), these parts sit proudly in my living room, my staging area:

CRAP. I still have a long way to go. Parts missing:

• Manual pedal kit
• Master & slave pump w/ hosings
• Clutch fork
• Gearbox mount
• Gear knob
• Rubber parts such as guibo and shifter boot

(List not exhaustive, will add as I go)So what's the action plan? Stage 1: Refurbish clutchStage 2: Procure the missing parts from stockistStage 3: ASSEMBLE ( DIY 2)

 

[stig]

Stage 1: Refurbish clutch

Let's take a look at what's inside:

Friction plate looks a little worse for the wear isn't it? Anybody got opinions before I move on to refurbish these? Or should I be more worried about the clutch plate?

I'm going to turbo this car so I'm kind of worried about my clutch condition.

 

[Mtigo]

dont forget to get Rear Diff Differential Axle for manual gearbox

 

[seewai]

dont forget to get Rear Diff Differential Axle for manual gearbox

Yeah...LSD..........

 

[JFT63]

Just realised your thread stig...this is a huge DIY for me..good luck on yr project..my morale support be with you mate...

 

[stig]

Just realised your thread stig...this is a huge DIY for me..good luck on yr project..my morale support be with you mate...

Thanks! Where are you at now? Collecting parts? If you have patience, do it piece by piece like me. If not just look for a complete set.

Mtigo, seewai: Keeping the stock diff (4.45) which comes with auto... a bit higher than the 4.1 with stock manual

 

[loafer]

You can refurbish the clutch shouldn't be a problem.

If you can find a single mass flywheel you can change the clutch to 3 puck,4 or 6 depending. That's around 300+.

Also the list of missing parts shouldn't cost you a lot if you get them brand new. Just need some time to order them.

Good luck with your DIY.

 

[Eggie86]

Wah Stiggy boy, all the best mate.

Tentatively how long before the end result can be viewed during the Subang TT? :biggrin:

 

[Chrix]

these parts sit proudly in my living room, my staging area

Most patient wife award goes to....*drum roll*

j/k

Good luck in your search, I'd be worth the trouble !

 

[John_Smith]

I know one day you'll take the dive...

 

[pussy]

Thanks! Where are you at now? Collecting parts? If you have patience, do it piece by piece like me. If not just look for a complete set.

Mtigo, seewai: Keeping the stock diff (4.45) which comes with auto... a bit higher than the 4.1 with stock manual

is your M50 B25 ? , then the Getrag you using is 1.1 final drive ?, if so, the stock original rear diff ratio is 3.15....not 4.1.

 

[clovi5]

is your M50 B25 ? , then the Getrag you using is 1.1 final drive ?, if so, the stock original rear diff ratio is 3.15....not 4.1.

if I'm not mistaken, Stig's is m43?

Btw looks like you're also looking for a manual clutch pedal. Please do inform me if you managed to locate one.

 

[ICEMAN 68]

wow looks like to much of crap which is still gonna cost more $$$$ ....

is the box in working order ...? ummmm

 

[pussy]

if I'm not mistaken, Stig's is m43?

Btw looks like you're also looking for a manual clutch pedal. Please do inform me if you managed to locate one.

even so, it's a M43, then it should be 3.45 original.

clutch pedal plus springs and clutch pump should be able to order.

here is the assembly:

The clutch line plus pump

 

[tehyw]

You can refurbish the clutch shouldn't be a problem.

If you can find a single mass flywheel you can change the clutch to 3 puck,4 or 6 depending. That's around 300+.

Also the list of missing parts shouldn't cost you a lot if you get them brand new. Just need some time to order them.

Good luck with your DIY.

eh loafer, dun messs with my frd lah.. he kena racun kao kao edi... he using twin mass i think...
btw, we have to visit that segambut clutch place soon! hehehe...

 

[tehyw]

oi, the clutch plate can buy new vr cheap (8.5"), no need refurbish.. ask our frd at bavarian auto... also need to check ur pressure plate still can pakai or not.. but dun worry lah, these pressure plates last forever wan lah..

4.45 diff is gona kill u tho... genting road ok lah.. city.. ahdui...

 

[pussy]

Here is the link on the diff ratio to be used: Item 01

http://www.realoem.com/bmw/showparts.do?model=CA92&mospid=47437&btnr=33_0370&hg=33&fg=05

 

[Mtigo]

oi, the clutch plate can buy new vr cheap (8.5"), no need refurbish.. ask our frd at bavarian auto... also need to check ur pressure plate still can pakai or not.. but dun worry lah, these pressure plates last forever wan lah..

4.45 diff is gona kill u tho... genting road ok lah.. city.. ahdui...

i think about 500meter you can finish all your 5th gear...i have this prob on my previous ride....in 1 month you can heard a sound ketak ketak ketak from your gear box. 100km/j your rpm is 4.5k. For M43 diff ratio should be 3.45

 

[stig]

wow looks like to much of crap which is still gonna cost more $$$$ ....

is the box in working order ...? ummmm

Iceman, yes I don't know if the gearbox is in working order but I have a standby box ! Else just rebuild la and puas hati!

To the rest commenting regarding the diff, I guess I learn something new everyday - might have to hunt for a diff as well. What's the average price for the 4 potter diff? I have a 6 potter 3.64 sitting around the house, might use that but have to get drive shafts

 

[stig]

After sahur @ McD Pusat Bandar Damansara:

If only I had a manual tranny, I would have pushed it downhill to start it up.