BMW E61 535D MANUAL SWAP - THE CAR BMW NEVER BUILT!!
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- čas přidán 21. 08. 2024
- - In this video we show you our Manual 535d E61, how it was built and what we think of it!
- Cost of swap - £500 as we sold may of the donor car bits to recoupe costs.
- Parts List:
E60 530d Manual Box
E60 530d LUK DMF (new)
E60 550i V8 Manual Clutch (uprated Darkside Developments)
E60 530d Manual Diff & Prop
E60 Manual Pedal Box
E60 Manual Linkage
E60 530d Manual Slave
Huge bmw order for all shifter bushes and rebuild bits we chose to do (not essential)
Custom Braided Slave line,
Master rubber hose.
- Additional Work (not on camera):
Ecu Work GKR
Coding (in house)
EGR Delete
DPF Delete
Swirl Flap Delete
All New Vac lines.
Huge thanks to all companies & individuals involved
- We hope you enjoy this video, we plan to bring you lots more content like this, let us know what you think of this video, drop us a like or a comment if you want to see more, also don't forget to subscribe for more content!!
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- Feel free to comment anything additional you would like to see as we always have a project or two on the go!
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Some big brain wiring and coding going on here
Impressive stuff mate ;)
Appreciated it mate, coming from you I’ll take that, thank you buddy 🤙
About time somebody did this!
Hey mate, only just found this video, but nice to see the 530d did its job 😊
For sure!! Thank you buddy 🙏
This is just awesomen. I really can't say enough good words for this video
Thanks bro appreciate the kind words 🤙
great video
Greatly Appreciated, Thanks
Your happy about the increased fuel consumption?! And do you offer this as a service?
Great job mate👍
Could You help me? Did you have any errors like that write them down after the whole operation?
For me it doesn't show any errors on the clocks or on the central display, but it does in INPA and ISTA... besides, the radiator fan turns on and I have to disconnect the connector.
Here are the errors I have:
No communication possible with: Transmission control unit
DDE: Electric fan, activation
Message (transmission data, OxBA) defective, receiver DDE, transmitter EGS
Message (transmission data 2, Ox1A2) defective, receiver DDE, transmitter EGS/S
Message (torque transmission, OxB5) defective, receiver DDE, transmitter EGS/ST
PLEASE HELP😢😢 becouse i dont know how to fix it
Nice build wanted to ask what gearbox best to chose for E 60 swap from 2.0 to 3.0 diesel and what else will needed to do that swap apart of electronics
It’s all in the video buddy, and 3.0 diesel box 👍
Heya mate, great video thanks. Could you let me know what exactly did you order from bmw with linkage bushings etc? Thanks
Ordered all from bmw using Real oem as reference 👍
Thought they only did auto as the torque was high causing breakages on the 535d tt
Great info,thanks for taking the time to put this video together.
I have a couple of questions if you don't mind.
1.Any one kept 535d diff and if so does gearing work for everyday use?
2.How much roughly does it cost to get 535d evu converted to manual.
Help,my auto is dieing fast!!!!!
Ta,
Stu.
Diff wise ratios are different so I would advise a manual diff, but it’s up to you.
Speak to GKR Performance - Glen Wilding, he’s a top bloke! And will price your ecu job, tell him what diff etc and he will input the ratio’s accordingly.
P.s thanks for kind words 💪
Clutch switch pin 1 - ground
Clutch switch pin 2 - engine control pin 50
Clutch switch pin 3 - CAS module pin 3
Clutch switch pin 4 - CAS module pin 41
Reverse switch pin 1 - ground
Reverse switch pin 2 - FRM module pin 13
It is correct ? Thank you very much :)
It was correct for my car, then a lot of coding to code all the modules from auto to manual, this was the hardest part and the most likely to damage part so I did off camera 👍 good luck with the swap if you go ahead 👌
@@wds_originals Yes this week, thanks for the info in the video :)
@@marejo899 good man, all I’d say is don’t go too mad on the torque unless you’re going single mass flywheel which vibrate like mad, mine being a daily I kept the dmf and held the torque at 800nm! 👍
this process would be the same for a 530i m54b40 query?
@@jeshuagonzalez8495 Slightly different wiring, some of the pins do match however. For the m54 powered e60's it's
Clutch switch pin 1= ground (brown/black)
Clutch switch pin 2 (blue/brown) to pin 23 on DME connector X60004 (black 40 pin connector)
Clutch switch pin 3 (Violet/yellow) to pin 3 on CAS
Clutch switch pin 4 (blue/black) to pin 41 on CAS (pin 41 occupied by auto trans signal wire, splice in)
Reverse switch signal (grey/purple) to pin 13 on light module
Reverse switch ground (brown)
Then you cut and solder together the canbus wires on the trans harness matching the colors.
Then using ncs expert remove $205 from the vehicle order in the cas and light module, default code cas, light module, kombi, dsc and szm modules
Clear variant adaptations in inpa.
Engine Module ms45.1 -> F5 - Status -> F1 - Digital Values -> F5 - Vehicle Options or Equipment
In this menu you will see a bunch of dots. Look for Automatic Gearbox. It may also be in German, Automatik Getriebe. If it's filled in, go to F8 - Clear -> F1 - Transmission.
After that you need to go back and clear the error memory then turn the key off and a wait a few seconds, then turn the key back on.
It will now start with the clutch instead of the brake, but you will have to hold the key until the engine start because manuals do not have comfort start, at least on pre push button start models.
And that's how you manual swap an m54 powered e60, everything will work as normal, abs, cruise control and traction control with no errors.
amazing
Thanks buddy!
Love you work! Is it possible to use 520d as a manual donor? thanks
No, the 2.0d box ratio’s are different, and I don’t think the gearbox bell housing would match.
Hi, what do you think would it be possible to manual swap BMW G30 3.0 or easier to engine swap 3.0 to BMW g30 2.0 manual version? Is that even possible? Cause there is not one 3.0 manual version on market, only 2.0 manuals.
very good video, there is also one for e39, I'm interested
Would love to see this done on a e9x 335d
Can be done very much the same swap just different chassis 👍
Then you have me trying to get and 8hp on a manual e46 😅
Perfect job , how much can stock clutch hold any idea
Thanks buddy,
Clutch in this isn’t stock, a stock clutch and flywheel is good for 320hp/700nm from what I understand 👍
@@wds_originals need a 335i clutch
@@vikingshpvs465 as per video I ran a 550i v8 manual clutch setup 👍
I may be missing something obvious but the last bit of wiring in video(yellow yellow twisted together and black black twisted together) where do they come from,/go to???🤔.
Ta.
They are canbus wires, and need looping in order for the modules to communicate 👍 hope this helps
Didn't want to start chopping the wrong wiring 😉.
Thanks for the excellent response as always👌
@@wds_originalscanbus wires from the 2 auto plugs in the ecu box? Doing a 35d swap in a e87 manual did not know About the wires twisting together, would like to get in contact with u
@@delanosieuw1954 drop me a message on Instagram 👍
hello, if I do exactly the same as you, only in the 525d 177km version it will be correct. Is there a difference with cables??
Personally I wouldn’t bother, just sell yours and buy a manual, they made those cars as manuals! But yes process should be similar but I can’t guarantee it’ll be exactly the same.
Nice car 😍
Can you give me the link or email, were did you sent your ecu for manual coding?
Hi mate what flywheel you used and clutch?
I'm doing swap now as well and heard that N57 flywheel + 550i clutch??
Luk dual mass, 550i clutch 👍
Awesome man. Please follow me as I only buy these 535d and I am hoping to open my own garage soon where I modifi these. How I the manual swap. Can the gearbox handle the torque
Good luck with the venture bro!
Gearbox handles it just fine 🤙
@@wds_originals I build a hybrid turbo monster last year 475bhp 900nmt. Check out some of my videos please
Would you be interested in doing the wiring and the coding on mine of I change the gearbox and pedals
Afraid not, I only work on my own cars at this stage, sorry!
What are differences between engines M57D30(306D3) 30d and M57D30(306D5) 35d fl? Thanks.
No diff change?? I did my 335d 5yrs ago i used the 330d diff to get the gearing right!
As per video diff swapped to a 530d and all the ratio’s then input into the ecu during mapping 👍
@@wds_originals Why are the ratios in put in the ecu when the ecu no longer controls the gear box?
@@lewiscollins1045 that’s probably a question for Glen @ GKR, but from my understanding the map was boost by gear, which required the changes in ratio to get the most from it.
Hi where did you get the long clutch pipe from
Wouldn’t it have been easier to just put a hybrid turbo on a 30d manual😂
No because the 535d twin turbo setup is totally different power delivery & I already owned this when the box went 👍
Put a biturbo on a 530d manual would be the way
Question is the driveshaft length on the sedan the same as the wagon?
Fitst part is diffrent
Hi! Is the clutch still ok? What do you think is the reasonable power/torque numbers for the clutch to stay reliable for the daily use? Doing the swap now but don`t wanna go ceramic and single mass and struggling to choose a correct disc/plate setup. Thanks!
550i clutch is best for up to 850nm, flywheel from 530d will start to shit itself above 650nm but single mass isn’t healthy for these engines
So,în UK 535d didn't sold with manual ghear box?
535d never came with a manual box
why go from auto to manual? just asking bc i want an e60/61 in the future.
Auto were limited to 750nm which is not a lot since you can pull a lot more from this car. Lci had an updated gearbox and could handle a little bit more but not much. You could probably pull out 800+nm with an intercooler upgrade, ECU tune, downpipe and a straightpipe for sure.
Will the gearbox hold if you were to increase power ?
Put simply, NO! The flywheel is the current limiting point for this car, you’d want to go single mass flywheel for more power but I daily mine & don’t want the single mass vibrations and it’s not slow as it is, so as a daily I’m more than happy with it 👍
8hp swap xD, then its the best daily.
@@wds_originals the LUK DMF kit can handle up to 400bhp no problems
@@iDriveNotxDrive it’s the torque that it can not handle 👍
Hey mate, how did you fix the problem with fan after swap ? I did swap on my 535d, everything works fine except the fan keep running all the time. Thanks in advance
Auxiliary fan? All in the coding process, code it to come on at a certain temp, I never had any issues, heard a few people say about it, but it’s clearly all in the wiring / coding process!? Not an issue I came across. Sorry to not be of help.
Hello, I personally made this swap on my e-60 535d, I can say that it was the worst decision I ever made in terms of tuning... that's how I say it... I invested over 3 thousand euros in everything that consists of clutch / box / cardan / software and etc..
Double mass clutch and ceramic clutch disc with 4 pucks and a reinforced pressure plate, resistance up to 800+nm were used
+ other new tracks.
Some money and time lost for nothing... with the stock engine, after being used for over 3 months, the clutch kit started to show signs of fatigue, the car is used every day in normal and sport driving mode and dashes, without bourn and without hoops ... and it doesn't even feel like it would shoot better... with the manual gearbox... on the contrary... the automatic beats the manual dash...
If you want a good swap, switch to the F10 box code 8hp70 with management from TurboLamik and you will see huge differences... not on the manual... the manual is fixed at 0 and even below the automatic... I'm telling you from my own experience... And regarding your problem, it is due to the DPF, you turn the DPF off and the problem with the fan goes away. success and luck
@@GhearaaaRo Im not arguing at all, tuning wise the auto box is probably better, if you want to do a manual swap properly for Tunning a single mass flywheel and balance the crank to it would be the best option as it’ll be the dual mass that gives first as they aren’t rated for the torque!
Personally I did mine for towing reason’s and a dead autobox, manual swap was far cheaper as it cost me all of about £300 after I’d sold all the bits from donor car etc. I just prefer manual’s to auto’s and it was best for me given the car was my daily and I didn’t care massively for tuning, as long as it was quick enough and reliable I was happy 👍
@@wds_originals Hello, yes, it's exactly what you say, this box is perfect for a trailer. for speed and or racing, the manual box is equal to 0, as I said. and regarding the simple mass of the flywheel, think that I broke 4 cardan flanges, with the simple mass, because it vibrates extremely badly when starting from a standstill, I'm not saying to get over it. and that the double mass does not last long because there are many Nm in the middle... so as an idea in terms of tuning/modifications m57b30tu 272hp/286hp Manual conversion is good for carrying weight If you want to opt for competitions or compete with other 8hp70 cars, it is perfect from every point of view. I made the mistake of switching to the manual ... thinking that I would get a better time from 0-100.... Many confuse that the manual swap is holy and exceptional for speed... wrong...
@@GhearaaaRo agreed ZF8HP is the better option! Re single mass vibrations that’s why you balance the crank with the flywheel to remove these vibrations, however this is an engine build procedure! Which most won’t do given it being a simple manual swap. Regardless I was happy with the result and I’m sorry you’re not overly satisfied, but hopefully you’ll get there bro 👌
Does anyone know if the manual gearbox from 530i will mate to the 530xi without any modifications?
Does the cruise control work after the swap?
Never been able to get mine to work, also 535d with manual swap
Does this work with lci if it does can you fit a pre lci box
Where did you buy custom clutch line?
Same for e63?
I’m not 100% sure buddy.
Anyone know if i can use a 550i clutch and flywheel to a n53 engine?
What midlift do you use?
recode to manual CAS, DDE, DSC and clocks?
Correct
Cześć Kamyk...czy słusznie myślę, że trzeba zrobić następujące czynności?? Tzn:
- usunąć z vinu automat i wpisać manual
- przekodować cas i lma do tej nowej serii z manualem
- przekodować kombi, dsc i dde do nowej serii z manualem
Czy ewentualnie winkiem muszę aktualizować soft pod tą nową zmianę na manuala?
Czy programy modułów zostają te same czy wymagają przekodowania??
@@MarioMario-xz4ye ja niestety sam tego nie ogarnąłem chodzi mi o same kodowania przyjechał do mnie gość i w 30 minut wszystko było ogarnięte
@@KamykGarage Kolego a czy masz jakieś błędy w inpa po konwersji bo u mnie jest kilka o braku automatu oraz włącza mi się wentylator chłodnicy ...czy miałeś może takie objawy? Jeśli mogę to bardzo Cię proszę o pomoc i z góry dziękuję za jakąkolwiek podpowiedź.
@@MarioMario-xz4ye też tak miałem na początku że wentylator się włączała bo sterownik dalej szukał automatu i nie pozwalał przegrzać skrzyni, a po dalszym kodowaniu już tego nie było. Niestety ja sam tego nie robiłem. Jak do tej pory u mnie jest wszystko ok nie ma żadnych błędów
Hi ,still going strong?
8000 miles later, she is still performing very well yes thank you 👍
What bolt pattern is the crankshaft, I can get a complete set from a 525d
I believe the gearbox is the same on the 525d’s as they are also 3.0 m57’s so I would assume so yes. But I’m not 100% sure, maybe do a bit more research first before taking my word for it.
How much do you charge to do this mate
What did you do to stop the rad fan coming on full time after the swap mate?
Hey mate, did you fix your issue with the fan ? Mine on 535d after swap to manual is also always rubbing none stop.
You turn the DPF off and the problem with the fan goes away
Are you sure ? I deleted dpf,egr and cat years before converting car to manual
Yes, I'm 100% sure, I had the same problem before the swap, the old owner turned off the DPF... the surprise was that it wasn't coded properly... the car was continuously regenerating... You I say that this is 100% the problem. It is not coded properly or is not fully coded.
the fan will kick on, if the ECU is not correctly coded . you will probably have a gearbox fault, if you´re looking in INPA under DME..
the fan will kick on, on high speed, if the gearbox temperature is high, or communication is lost with the gearbox..
did the swap on my 530d hybrid E61 3 years ago, I did reflash my ECU with a manual file.. you can do so by using WinKFP.. you will be needing to do a new remap (if you have one) .. after the flash
Treat yourself to a soldering iron...
Could someone go into a little more detail on the reverse light wiring please?
I haven't started the conversion yet but want to have full understanding before I do
Regards
The Village Idiot.
It’s all in the coding process to re program the lcm module to talk to the reverse switch.
☠️ I wouldn’t do this to a E60 M5 and my guy done this to a 2004 535D 😟 what a waste of money never to be seen again the car is still worth £3500 even with all that work 😭
Yes it is for the ones that like tourings
You could have just cleared the auto gearbox out of the digital values in inpa instead of sending the dme off to be reprogrammed.
Maybe but I also changed the diff to run 530d ratio’s so the map would have been incorrect, especially as it was mapped with boost by gear, got dpf deleted and egr deleted all at the same time, so needed to be properly mapped regardless 👍
For this conversation need i new soft(reprogramming) or only with inpa change value on manual?
Dose the drive shaft has to be modified?
Ran the 530d prop and 530d diff, 535d shafts bolt up 👍 no mods required
Did you fit the rear diff cover/cooling fins from 35d to the 30d diff?
I put a quaife lsd in my 35d when it was an auto,so just retained diff and used the 30d propshaft when i went manual
@@leadingees smart way of doing it, I like it!