PART 2: BMW E60 M5 SMG to Manual Swap (Mechanical Work)

This is part 2 of a 3 part series devoted to 6-speed manual swapping a 2006 BMW E60 M5. In this segment, I detail the mechanical requirements of the job including the transmission, driveshaft, shifter/linkage, pedals, heat shields, center console trim, steering wheel, and more.
BMW Parts with a Lifetime Warranty from FCP Euro: www.fcpeuro.com
Resources Spreadsheet: tinyurl.com/49...
M5Board Thread: www.m5board.co...
E39Source website: www.e39source.com
Help support E39Source by donating: www.e39source.c...

[@cyyeung4879]

NA V10, RWD, MANUAL that's what a good car is made

[@ejragolta]

Congrats Ryan - I know you wanted to sell the E60 a few years back but I'm glad that you & your father got to keep it and make new memories like this with it! You'll be shocked how much fun this car is with the 6MT.

[@yoamen9205]

congrats on the swap ryan you did really a great job and i really enjoy you're quality content

[@E39Source]

Thank you!

[@jamest5149]

Please do a final comments, review and comparisons between the manual and SMG👍

[@KelzCasa]

This videos are amazing, man! I plan on getting an E60 M5 some time this year, and come hell or high water, it will be manual, even if this is the only option when the time comes! 🤘🏽

[@hffvdbl]

Fantastic video. Watched both parts today. So thoughtful of you to share your knowledge and expertise to such a broad audience.

[@leroyleggs7606]

That is Awesome it's good to know when my SMG goes out I have the option to go Manual.

[@philippk1125]

I live in Austria, so we only have SMG M5s, but my M5 is already so much fun with the SMG, I couldn't imagine the manual.

[@vojvoda-draza]

how are the rod bearings

[@paulc2711]

@@vojvoda-draza you're stupid and too poor, buy something you can afford, stop looking at m5s, these cars are not for empty pockets who can't afford simple maintenance like rod bearings.

[@Maxi-ff6to]

Red da nix ein

[@Markjw25]

Excellent work. Stuff like that can be exhausting, but the end result is beyond worth it! Also would love to see an in depth video of that lovely E36.

[@dayalanvelan3070]

Awesome video and informative. Your car looks stunning . A masterpiece of German engineering now with manual . God Bless

[@MvanSst]

Nice video, it helped me with the swap. I installed the hydraulic clutchline without removing the drivers seat. i did pulled back the carpetting to install the clutchline. The flywheel from the smg can be used for the manual according to a contact that did the swap. i cant confirm that, im still building. i removed the brakebooster and than pulled out the pedal assembly to easily install the clutchpedal and parts.

[@E39Source]

Thanks for commenting and for the information! I'd be very curious about that flywheel. Good luck with the rest of the swap.

[@DJizz82]

I’m blown away & love this work !!!!! I want to swap my e60 M5 to be converted to a 6 speed

[@DuaneMoore]

What’s up brother . You know it’s sad that we put our hearts in making videos for people . Not sure how this series would ever get a thumbs down. I get my share also ;) Gods work Ryan ❤️😇

[@E39Source]

Thank you Duane! There will always be haters, unfortunately.

[@vitoroliveira3115]

This is so detailed! I´ll buy a bomb like this just to do this swap! I love you

[@eddd6827]

Wow what a video! Thanks for all info you are giving us!!!! ❤️

[@jordynmarie7766]

THANK YOU. My tranny shat out on my e60 550i, gonna be a fun project to manual swap!

[@francescosaccaggi6427]

I would love for you do the review between the two! Thanks for the quality content!

[@gagelloyd5513]

looks awesome... very clean swap

[@E39Source]

Thank you!

[@andybell1983]

Comprehensive and super clean install! Congrats :D

[@MTBSHOGUN]

Love the attention to detail Ryan ... I recently went from e39 to a e60 08 SMG ///M5 I miss the man trans but kinda like the SMG.

[@AndrewKidd14145]

Love fcp euro, and ecs tuning. Never had issues finding parts. Although I miss bavauto 😭

[@torygyberg8837]

Great stuff, enjoyed every minute!!

[@BMWarrior1]

Fantastic video Ryan - love your passion,knowledge and drive. looking forward to future videos.

[@Tocsad]

Big job, keep up the good work!

[@Fee.1]

You’re a international hero

[@salem99099]

your M5's are GEMS

[@davidmitchell5638]

This is just just awesome!!

[@InitialD604]

such awesome content, please give us a ride along!!!

[@Consoft04]

Amazing man!! Love the video!!

[@JrIza_914]

I have a non-m e60 and this has motivated me to do a manual swap on my car. I would just nee help on the wiring.

[@TurdFurgison42]

Awesome job Ryan! Can't wait to see the rest of this, I would like a comparison video on the SMG vs 6 speed. You are making me want to swap mine to a manual now...

[@FishFind3000]

20:15 I bet it just reads the throttle signal and if it goes past the switches area it’s in kick down mode. Switch just makes it obvious for us that it’s happening. I wonder if that’s gonna affect the engines tuning with the throttle still maybe thinking there’s a lockdown area.

[@E39Source]

The lock-down area is still there, you just don't feel the switch anymore. It still actuates 0-100% in INPA, like before.

[@Leonidae]

Ah yes, the best reliability mod for E60 M5 xD

[@andrewmattera6205]

I don’t judge you for driving barefoot. I do that a lot myself, I feel that I get better control of the throttle that way

[@FishFind3000]

I feel like I have less control when barefoot. I don’t like braking barefoot.

[@shatolamm9727]

I have 550i and one day I will swap it too ☺️

[@hansbrix2495]

Nice job. Can you advise who built the custom driveshaft? A review would be good too especially thoughts to compare e39 vs e60 manual (as well as SMG).

[@E39Source]

DriveshaftPro in San Diego did the driveshaft. I'll see about doing a review!

[@chrisa9999]

Typically Awesome!

[@SlumRacing]

I know you are a bmw guy, but I own a giulia qv and want to convert it to the manual like they have in italy. I'm sure the whole giulia forum would be interested.

[@alexandrunicolae9460]

those little yellow springs on the pressure plate should be compressed all the way, before installing that wear-adjustable clutch, otherwise you find yourself wearing out the clutch prematurely...other than that,great job

[@fawazalmutairi174]

Perfect 👌

[@streetrider1987]

Great job!

[@ghostman5298]

Hi there, I converted my m5 to manual, can you please tell me the part nr for the tray with the edc button? Cheers

[@TheHeretic435]

Those white 'receptors' as you called them, in the dash, for dash trim , same E39 - is it normal for the little metal 'jaws' in them to bite so hard you got both hands behind the wood trim, fingers splayed to distribute the load evenly so as not to crack it (I did put a hairline crack in it), and a foot up on the dash pulling with all your might, until one of the pins clean rips out of the aluminium backing on trim? I never saw anything like it. I tried silicone spray, working it side to side etc.

[@E39Source]

They absolutely shouldn't be that tight. I wonder if somebody before had those receptors break apart and then the glued the trim on?

[@NathanKopilec]

Thanks a lot for this video! From everything I've read online, I was led to believe that this couldn't be done without ripping the entire vehicle apart and replacing the entire vehicle harness (which I knew was ridiculous, but never found any instruction on how the harness would need to be modified). I just replaced a bunch of parts on the SMG and have a new clutch, so I probably won't be doing this anytime soon. I also like the SMG (when it's working properly). However, I would definitely consider doing a manual swap if I could convert the manual geartrain to non-synchromesh. Have you ever been inside the E9x M3 gearbox and know whether it would be feasible to replace the gear sets with ones that use synchroless dog rings? That would be super cool.

[@E39Source]

I've never opened the gearbox, and don't know much about that conversion. Sorry!

[@E39Source]

To make it 1:1 to a factory manual car, yeah, you would have to do that. But if you can handle making (and are okay with) a few pin changes and custom wire taps, it's not that bad!

[@NathanKopilec]

E39Source Awesome! I've already pretty heavily modified various areas of the vehicle's harness, so I have no issue with that. I think it's insane to completely tear the vehicle apart to replace the harness. Plenty of things are likely to be damaged or broken along the way as well. I don't think the interior of the vehicle would ever be quite as pristine as it once was if it were stripped.

[@User84977]

Please make an in depth review.

[@miguelalves3652]

wasn't esyer to install a manual cluch and keap the smg pump ? it was nice to keap a seven speed sequencial gearbox ,and operate the gears by the pedal shifters . do you think it's possible ?

[@E39Source]

So put a manual clutch in but shift with the paddles? That would be completely impossible.

[@miguelalves3652]

@@E39Source i dont know how a smg pump works but thanks anyway .

[@goodcars1578]

I love manual gearbox

[@Fee.1]

Whoa whoa whoa we are just going to accept defeat for a massive mystery of how the kickdown switch works? It has to communicate somehow or it’s not really what people think it is. It’s clearly not Wireless so what’s the deal. Fascinating

[@E39Source]

I think the kickdown switch is just for the driver, so they know they're at the floor? The throttle cable just moves that extra 1/4 inch to fully 'open' it as it is pressed.

[@Fee.1]

E39Source so it’s not actually a switch as much as tactile feedback and the programming is in the throttle (drive by wire?? Or no?) seems bizarre, I hope one day we can get the whole story that sort of thing fascinated me especially as it relates to people’s perception of something. It would be a neat experiment to have someone with the smg swap the throttle and see if there’s any noticeable difference in behavior.

[@Fee.1]

E39Source I wonder if your throttle cable is 1/4” longer than the manual models 😂

[@Fee.1]

E39Source last question, does this make any sense for someone buying a e60 right now in your view? Or only existing owners. I’m not familiar with the current cost delta

[@E39Source]

@@Fee.1 I think it is just tactile feedback. The throttle works from 0-100% 'open' with or without the switch. But with the switch, you are more aware when at you're at 95% and above. I'll make a video about who it makes senses for, but I would only recommend this for current and invested E60 M5 SMG owners.

[@oneman7638]

I wanted to sell mine, its an original 6 speed. I ended up putting 40k in it, and made it reliable.

[@budkovproductions6338]

Question if you don’t mind, did you have to do any coding or wiring for the initial start?

[@E39Source]

It won't crank until the wiring/coding has been completed.

[@User84977]

Love it

[@setperspective]

Awesome

[@myashafey5303]

Will you please help 😢 Swap my e60 but the reverse light not wairing I don't have the

[@E39Source]

I'd need the car in my shop to diagnose and repair this. Are you able to bring it to San Diego?

[@kierowik1]

Awesome Video!!! So which flywheel \ clutch combination you went with? Does the E92 flywheel and clutch fits or it needs to be specific for S85?

[@E39Source]

E9x M3 flywheel/clutch kit DO work for the E60 M5. We used the factory E60 M5 parts, though.

[@eduardopalma4238]

i am from brazil and i own a 545i motorsport v8 6hp28 and i was afraid of the pedal parts for the swap. I am so happy that you updated that video with so much quaility content, thank you very much, helped a lot. Thats a fucking expensive car in brazil, i am trying to buy the clutch parts on ebay, but i cant find, can u tell me if the e39 clutch pedal fits?? i just know that the zf 420g manual fits on 4.4 v8 e60, but i need the clutch pedal and the rest i can fabricate for... Thank you very much!

[@E39Source]

The E39 pedal should work

[@alexbryant5]

Do you think this adds value to the car? Great video!

[@E39Source]

It adds some, but not as much as it costs!

[@alexbryant5]

@@E39Source interesting. Here in Australia, we never received the manual so I expect or at least hope it would add some significant value being the only one known in the county. No doubt someone else has done it but I've never seen one here!

[@antfou2]

I know you might fine this comical, but are you offering this as a job to be done at your garage? Just asking for future reference with my e63 m6 haha

[@E39Source]

I am offering this service, please reach out at [e-mail]!

[@vysgarage]

Hi there! Amazing content, really great watch 👌🏻 I’m considering doing this swap at some point in the near future and was wondering if it is possible to use E9x m3 flywheel? Thanks

[@E39Source]

Thank you! I have since done another conversion for a customer, and we used the E9x M3 flywheel and clutch kit. It bolts on and functions 100%! At a fraction of the cost of the M5 parts.

[@vysgarage]

That’s great, thank you for getting back to me 👍🏻

[@jordicastano6242]

Amazing job here!! I have a question, which clutch kit and flywheel have u used? Is it the m3 e92? Thanks!

[@E39Source]

Thanks! We used the Genuine BMW (LUK) E60 M5 flywheel and clutch kit.

[@rankzwazhere]

Bro, love this content

[@pawelmakaruk]

Why orginal m5 e60 manual gearbox doesnt have power button? Thats mean that they have only 400 ps ?

[@E39Source]

You adjust the power configuration in iDrive and use the M button on the steering wheel to activate different modes.

[@dasburke]

what flywheel is being used?

[@E39Source]

We used the stock E60 M5 flywheel: bit.ly/2OksAzl BUT the E9x M3 flywheel works: bit.ly/2N8quSE

[@javiktm525]

Thank you very much for these videos, with them I will be able to convert from SMG to Manual :). The knowledge and value you bring is incredible, I am very grateful. I also wanted to ask you if the gearbox of the european m3 e92 is valid for the swap. The one you use in the video is 23002283601 GS6-53BZ - TJGC, and the European one is 23002283600 GS6-53BZ - JGC. Thank you!!

[@E39Source]

That should work fine!

[@javiktm525]

@@E39Source Thanks !!, and with the flywheel of the m3 e92, will the s85 be well compensated?

[@E39Source]

@@javiktm525 Not sure what you mean by compensated, but it will work just fine. Just like factory.

[@javiktm525]

@@E39Source I mean that since the m3 e92's flywheel has a different reference to that of the manual m5 e60, I don't know if the mass or weight of the m3 e92 flywheel may be different from that of the manual m5 e60, and affect the s85 in some way. I have also seen that they put the flywheel of the m5 e60 smg, but I no longer know if the box of the m3 e92 would be worth it.

[@E39Source]

@@javiktm525 I'm sure there is some subtle difference somewhere, though the E9x M3 gearbox, flywheel, and clutch kit all work just like the E60 M5's in my findings.

[@berfus7823]

what gearbox is that, does the e92 m3 manual gearbox bolt right on to the s85 ?

[@E39Source]

Yes, the E9x M3 gearbox works perfectly (along with clutch kit)

[@Bouhlev]

Hey man, would you have the Flywheel Torque Specs? I can’t find it in the sheet you linked. Thank you!

[@E39Source]

Hmm, it’s not there! My apologies. The spec is 105nm or 77.4lb/ft

[@Bouhlev]

E39Source hey man sorry for the bother again. But the driveshaft to the differential with the E12 bolts.. what is the torque spec? Some people say 85nm no TTY, but in your spreadsheet it says 40nm then it says 45nm to 45 degree, not to mention you have a custom driveshaft like you said….so I’m a little lost. Thanks again

[@E39Source]

@@Bouhlev The spec I referenced was specific to our E60 M5's bolt size/thread/type. If yours is the same, follow the published spec. Otherwise, I'd use NewTIS.info to determine the specific torque spec for your hardware. Our custom driveshaft/CV joint used factory BMW hardware.

[@AndrewKidd14145]

Do you need to program anything? Or just buy a wrecked manual and swap it all along with ecu and stuff.

[@E39Source]

LOTS of coding/programming for the DME, nav, DSC, general module, cluster, etc. Way easier to change settings than components. Most of the components would need to be programmed to the new car anyways.

[@vitojin9784]

Good Job! just wondering that e92m3 manual is gonna be direct swap if e60 m5 comes with a manual?

[@E39Source]

Direct swap, only difference is that the E9x M3 trans has an oil filter (E60 M5 manual does not) and the M3's uses an oil cooler that must be retrofit or just plumbed off.

[@vitojin9784]

@@E39Source Thanks a lot! valuable info! I was thinking that going with e92 6 speed for more sporty gear ratio, but just found out these two trans have similar ratios. Maybe e92 dct swap is interesting project too!

[@Fee.1]

Don’t you have a notorious video explaining why you prefer the e39? That still the case? Still make sense to buy an e39 over an e60?

[@E39Source]

I haven't made that video, I feel like it's fairly obvious lol.

[@Fee.1]

E39Source I must be thinking of someone else’s video. Or just misremembering the subject. I thought at the time you’d said you had no real desire to own one, even though your dad did or something idk my memory is clearly terrible

[@E39Source]

@@Fee.1 I do not have a desire to own one, I feel that the E39 M5 is a better suited car for my needs and wants.

[@The_North0]

so you are not going to wait for DCT becomes available for E60 M5?

[@E39Source]

That's no better than the SMG. The manual is what make the car special!

[@catalinosolorzano7054]

It won't allow me to loom at the spreadsheet

[@E39Source]

I just verified that the link is indeed working. It likely won't work on a smartphone though, you'll need to use a computer.

[@catalinosolorzano7054]

@@E39Source oh I see I'm sure using a smartphone

[@M-TEKKK]

Gg good video

[@umarmahmood4511]

Would it be a good idea to make a cooler?

[@E39Source]

If you drive the car very hard, sure!

[@hffvdbl]

What happened to part 3

[@E39Source]

Right here kzbin.info/www/bejne/kJ3bY4OwfNJ_ock

[@ep9321]

Did you use E92 manual setup?

[@E39Source]

E92 M3 transmission, yes

[@JustinLinares-er6lc]

Hey Ryan! What is your email again? I've been lucky enough to locate a 09' M3 transmission and would love to possibly work with you on doing this to my 08' E60 M5! If you're open to it of course! Thanks again for your time!

[@E39Source]

Hey Justin, thanks for the comment! Please email me at [e-mail], I'd love to work with you!

[@DropTopJordan]

How much for the swap?

[@E39Source]

Parts list/prices are in a documented linked in the description to this video. If you're curious about my labor rate, please inquire at [e-mail]

[@johnpacheco232]

Can you do mine ??

[@E39Source]

I am offering this service to my customers! Please email me at [e-mail] for details :)

[@MikeyPraz2121]

This is more of a warning to anyone thinking about attempting this….Don’t! Lol

[@mrgqbmw4818]

Would you like to do mines

[@E39Source]

Bring it to the shop!

[@alejandrovelazquez2378]

👏🏻🦾🏴‍☠️

[@simonnim321]

You should help me with mines too! -_^

[@DJizz82]

Do you have an Instagram ?

[@E39Source]

Thank you! And yes, @E39Source