91 318is Never ending project(s) journal

[monty23psk]

the tranny skid plate? I will after it is all button up. I want to make sure it works fine because the m42 stock oxygen sensor location is in the way. As a worst case, I will just sell this plate but pretty sure I can mock something up this weekend.

[rzerob]

You are not planning to paint it?

[Gkwan]

Wow great work! Looks the the never ending 318is may be ending soon!

[monty23psk]

Once the heat shields were dried, I went to install the new driveshaft and realized the 4 knurled bolts at the rear end knuckle were not there. I had to order them from BMW and finally installed them on the knuckle and installed the driveshaft in the car for a test run before installing all the shields and exhaust.

Here are the new bolts. Hammered them in with a ratchet extension.


Bolts installed:


All shields installed with support bar and some new hardware as I was missing some or they were too corroded for my taste. The all black looks cleans it up a little.


I then have a few new parts for the exhaust installation. I cleaned up the hanger bracket, tranny bracket and installed new rubber mounts:





I then took here for a spin. Big smile on my face. No issues, shifts smoothly and the short throws are just amazing. But with a new clutch and the SS, it was like driving stick for the first time. My timing is off. The clutch engages so close to the top like a new car and I have been use to it engaging midway to all the way down. Also, it has been a year since I drove her an only about 2 weeks worth of manual with rentals in Europe. I will keep driving it and maybe look into a clutch stop, who knows. Just glad to have the car back on the road. Need to finish the tranny protection plate install and a good car wash and she is 100% complete for this project.

[monty23psk]

[monty23psk]

While waiting for some new bolts for the driveshaft from the dealer, I decided to cleanup the 2 heat shields.

Here is the rear section which has some surface rust but overall for its age its in very good condition. I took a wire wheel to it and then painted it with a matt black spray paint from Rustoleum to help prevent more rust and it is designed for very high temps, I got it at Walmart.



Here is the larger shield cleaned. I forgot to take a picture of it before I started. Also, the sheild looks to have blotches but that is because it has just cleaned it and was still wet.



Here is the first piece painted with 2 coats. Will let it sit to cure. I will paint the other piece and post pics. I ran out of sun light due to some work on the e39. Its has a deeper black in person.

[monty23psk]

[ForcedFirebird]

Did you bleed the clutch yet? Easy way to do it alone - having installed many trans/clutches etc alone at my shop, learned a trick. With everything installed except the slave in the trans. System closed and filled with fluid, pull the clutch pedal up by hand. Go under the car and plunge the slave in/out several times. At first it will be easy by hand and start to get difficult. I then use one of the square ribs on the transmission to use both hand and plunge the slave in/out, you will actually hear the air bubbles going away and the slave rod will get REALLY difficult to push in at all. When you get to that point, install the slave in the transmission and you should have full clutch pedal, or maybe just a couple more pumps of the pedal and it will be completely bled. I NEVER even loosen the slave bleeder and have been doing it this way for years.

[Gkwan]

Nice progress! This thread is an inspiration for my 318is!

[monty23psk]

Another update and it has been very slow due to lots of traveling for work and then family time when I am home with the little ones. I plan on having it back on the road before the end of the year as I am not on vacation until 2017. Here are some shots of the prep and now installed tranny. Working on DSSR with UUC as the 215mm is too short and will probably need the 283mm from an e39 m5. Waiting on call back from Rob at UUC but in an old thread from SimonS which the same car, that is what he needed to do.

On to the pics:

new parts, output seals and bushing:


Seals installed, forgot to take on of trans output seal before installing the coupler:


Tranny installed, boy it was heavy to do it by yourself but I got it. I used new bellhousing bolts.



I now have the slave cylinder installed and starter in, just need to bolt it. I need to finish working on the DSSR but I have the EVO3 SSK installed. Clutch pedal has no bidding, now need the lever to test throws before turning it on.

[monty23psk]

Here is the AGA bronze clutch pin installed:

[monty23psk]

Adding a few more pics of the process. Replaced the transmission input seal. I reused the metal casing and just swapped in a new seal. I also got new bolts and washers from BMW. All buttoned up with Blue Hylomar for extra sealant power. I did also clean up in the inside of of the bell-housing as much as possible, wire wheel and plastic pic/scraper. The outside is about 80% clean as well. Next is the new bronze guide pin, output seal and selector rod bushing. It was this plastic piece that sheared off and started this whole process.

[monty23psk]

Today I installed my lighten, about 3 lbs, resurfaced and rebalanced m20 flywheel. I installed it with stock BMW m20 bolts. Torqued it to factory spec. It is nice to have the flywheel lock pin to hold it in. THen I installed the ClutchMasters stage1 m20 clutch kit with new BMW torx bolts. Torqued that to spec as well. Just need to finish cleaning up the bellhousing and replacing the seals, and replace the ATF.

Flywheel installed:


New Kit:


Clutch aligned and installed:

[econti]

Thanks heaps for the link. I've been after one for ages lol

[monty23psk]

I have been traveling for the last 2 weeks so everything went on hold. Today I went by to pick up the flywheel from the machine shop. All looks good and then when I came home, I did a mock up before I send it out for lightening/balance/resurfacing.

All fits like a glove. The machine show which is only 10 blocks from my house was about to remove the ring from the m42 flywheel and add it to the m20 one. They did have to shave a little from the diameter of the m20 fw. Then I requested they add the 8mm TDC and 180 degree TDC holes so I can still use my flywheel lock pin. With this, I can use my m42 starter and no modification needed. Also, no need to buy the m20 start. The lightening/resurface cost will surely be more expensive than what I paid.

One thing to note is that the spacer plate that needs to be removed from the m42 flywheel by drilling through the rivets, will need one hole widen to fit the rear crank hub guide. The TDC hole is the one in between the two dimples on the inner hole.

Monday I take it to the clutch place. Will keep cleaning items ans start to work on the seals for the transmission. I am in town for the next month so I really hope I can finish it by then.

Here is a picture of the m42 fw on the left, the loose m20 ring gear, the spacer with the widen hole and the m20 flywheel, with TDC marks and the ring gear installed.

Something to note, the new BMW provided m20 flywheel bolts already come with yellow threadlocker applied.