M30 install into calypso cab. Back on the road :)

[mcbonio]

How's the gbox issue Jim?? All sorted now?

[jimbom30cab]

hope so mate, should be back home now so looking forward to seeing it when i get back

[mcbonio]

Brilliant, how did you like the power increase on the M30 Jim? Or didn't really open it up much?

[jimbom30cab]

well, not so good really

they have changed the box and it selects gears when the engine is off so the new box seems fine

but pressing the clutch with the engine running is not allowing the selection of any gears

I have checked all the parts are right

the box is a H pattern e28 535i box
flywheel and clutch kit is e28 m535i (same parts used in the non-m 535i also)

However.....the slave cylinder is an DP4L cheapy one

but chatting to the mechanic today he thinks he didn't fit the release bearing properly and it could be causing problems.

basically pressing the clutch makes a nasty noise and no gear selection is possible

what a pain !!!

gearbox out again

[mcbonio]

Feel for you man I really do.

[jimbom30cab]

Well mate, the garage are doing the work and it isn't costing me for them to re-do it so hopefully it will be sorted by Wednesday . . I hope as I can't think what else to do !

[Rav335uk]

You got the correct release bearing?

[jimbom30cab]

Well I am using e34 535 but I believe they are all the same

[jimbom30cab]

http://www.realoem.com/bmw/partxref.do?part=21517521471

looks like it here

[jimbom30cab]

thanks Rav anyway for the idea, sorry to be so short in my reply, the kids were beating me up at the time.

I've double checked all the part numbers and the kit I have fitted and it all should be fine. It must be a problem with how they have fitted it all.

When the e34 gearbox was in it selected all the gears fine as I drove it a bit (except 3rd and 4th which was a gearbox fault)

the e28 box is identical to the e34 box and I've checked all the part numbers also

so must be the clutch arm/bearing fitted wrong, must be that, can't be anything else.

the joys !!!!

[Rav335uk]

COuld be the slave then, not enough reach?
Or the fork?

[jimbom30cab]

yes mate, I think you are dead on, it's like the slave doesn't have enough reach

I bought the slave from CP4L for a e34 535i so guessed it would be ok but looking at the below link the e28 535i is not on the list so maybe that's what I need then ?

I could get a genuine bmw slave for the actual e28 535i gearbox (guaranteed to fit), it's like £80 and there is no refund apparently , so they said if I don't need it.

i'm thinking I should do that.

http://www.realoem.com/bmw/partxref.do?part=21521157346

that's funny though actually as I have a e34 535i slave fitted at present to my m20b25 and it works perfectly.

i'm sure the slaves are all the same but maybe the dodgey CP4L slave is a duff ??

it really doesn't feel like that though to be honest, it actually feels like the clutch plate fingers are broken (unlikely) or the release bearing has rotated round and is now too far from the cover plate (but that just doesn't seem right)

i'm worried it's all wrong tbh and I can't work out why as everything on paper is dead right and it should work ok. You know what it's like, I've put so much time and money into this swap and it could all be wasted....i'd be mortified.....and so would the Mrs if she knew how much it has really cost. You know, you start thinking I could have given the kids the money instead and stuff like that and it makes you feel guilty

[Rav335uk]

I had the same crappy day too.
Put the front covers on today, torqued up the head, etc........
Then, I find out I have 3 allen key fillister head bolts left, and sump bolts.

Then, racking my brains, and wondering where the bloody hell they go, and my minds blank

Phoned Marc (Zaust) asking if he could remember, no go

So, came home, and looked through BMWFans, and after 15mins of looking, found out they were for the viscous/fan attachment

But the G/box issue imo will bee the slave.

[jimbom30cab]

Rav,

closer look on Realoem states:

e34 clutch slave cylinder = 12 OUTPUT CYLINDER CLUTCH D=22,20MM

e28 clutch slave cylinder = 14 OUTPUT CYLINDER CLUTCH D=20,64MM

so i'm guessing the 20mm and 64mm could be the travel distance of the piston

and for some reason (maybe the flywheel is a lot thinner on the e28) that the piston has to therefore travel further than the e34(with the thicker dual mass fly)

sounds possible would you think

i'm thinking I might have to go back to the garage slightly and let them know I gave them the wrong slave cylinder

what do you think Rav?

[jimbom30cab]

oh man, nightmare

you should have called me

I will PM you my number, if you need anything at all - call me straight away

jim

[Rav335uk]

Rav,

closer look on Realoem states:

e34 clutch slave cylinder = 12 OUTPUT CYLINDER CLUTCH D=22,20MM

e28 clutch slave cylinder = 14 OUTPUT CYLINDER CLUTCH D=20,64MM

so i'm guessing the 20mm and 64mm could be the travel distance of the piston

and for some reason (maybe the flywheel is a lot thinner on the e28) that the piston has to therefore travel further than the e34(with the thicker dual mass fly)

sounds possible would you think

i'm thinking I might have to go back to the garage slightly and let them know I gave them the wrong slave cylinder

what do you think Rav?

I think that looks spot on.
I used the M20 slave on the cab, but i'm running a dualmass fly in there.
I'm sure the slaves are different for the flywheels.

I'm going to be running a custom flywheel on this one, which is mad to the same thickeness as the dualmass one, and again using the M20 one.

[jimbom30cab]

well it seems mate that if the FW is the same thickness you can live with the "standard" e30 cylinder.

better get a e28 clutch slave on order

should I risk a GSF/ECP one or just get a BMW one to guarantee it works.

[Rav335uk]

I have a GSF M30 one on the cab, and that's been on there since I did the conversion.

[jimbom30cab]

cool,

where would you recommend getting a clutch kit ?

[Rav335uk]

I can't remember where I got my clutch from, but it wasn't GSF or ECP

[ImysE30]

I got mine from ECP as they were the only one's who sold the E28 one.

[jimbom30cab]

i'll be on the dog and bone in the morning then

did you use the e28 slave cylinder also mate?

[ImysE30]

Pretty sure i've got an M20 on there fitted.

[Rav335uk]

Pretty sure i've got an M20 on there fitted.

Dualmass fly then

[ImysE30]

Pretty sure i've got an M20 on there fitted.

Dualmass fly then

Nah single mass on mine fitted

[jimbom30cab]

Yup, sounds like it

funny thing is, it would be cheaper to buy Lee's DMF and clutch which is for sale on his thread than a new e28 slave cylinder !!

i'll get a new slave cylinder asap and pop round the garage very apologetically first thing monday

[jimbom30cab]

Right, I've ordered a new clutch kit and a new slave cylinder for an e28. 535i, same as the box and fly.

So when fitted it should I hope be all ok.

I got them from GSF in Portsmouth, guy there Neil is well into the old BMs, nice to talk with someone who understands it all. Most people ask for a reg and then look at you blank.

[Rav335uk]

I get the "Blank" look when I oerder parts at Sytners in Solihull.
One guy didn't even know what an "E30" was , there's confidence

[leeparkes]

You can use an E30 slave with both single and dual mass flys,

Just an idea,, what oil is in the box? if normal EP oil is used it can be a right bastid to get in gear when cold.

Before you go spending money put it in gear, foot on the clutch and see if it will start (be ready though as if it jolts forward you may end up with a car in the kitchen.

If it starts its not a clutch problem.

[jimbom30cab]

Thanks mate, it has ATF in there

It's defo a clutch related issue, I'm pretty sure of it.

See where we are by close of play on Wednesday.

Conversions hey, a roller coaster of emotions !

[leeparkes]

Whats your set up?
gearbox
clutch
fly
etc.....

[jimbom30cab]

GB - e28 m535i H pattern same as a e28 535i

Clutch kit - e28 m535i to be replaced with e28 535i - to be honest it makes sense to do this anyway the m and non-m 535 clutch kits are the same bmw part numbers

Fly - e28 M535i year 87

At present it is a e34 clutch slave cylinder which after doing a bit of Internet research is not right I believe

So I have ordered a e28 535i slave cylinder

Do you think I would need to change the clutch master cylinder?

I am convinced now that the DMF slave cylinder will not extend enough to operate the clutch when a SMF is fitted

I'll test the theory and report back

Mmmmmmm

I'm definitely in the "which I hadn't bothered this conversion now" place

Althought next time I will buy a complete working engine with box so I know it will all go back in right

There is a lot to learn with all this

[leeparkes]

All of the above should work, the only thing im not sure about is the slave, as said above ive used an E30 slave with BOTH single and dual flywheels.

[jimbom30cab]

D you think it's worth changing the clutch master cylinder also?

[Rav335uk]

You can do, as I changed mine because it was leaking back through the seals.
Takes about 30-40 mins to swap over, and they're not pocketbreaking wither, about £20-£25 from GSF