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AZBMW Forums › Model Specific Discussion › 5-8 Series › Desertpir8's '92 535iM project *photos*
Desertpir8's '92 535iM project *photos*
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1_2race
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PostPosted: Sun Jun 05, 2011 10:13 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Outstanding work. As many others have stated car look fantastic.

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MeineS7ven
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PostPosted: Sat Jul 30, 2011 5:43 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Looks like it needed a little bit of work but coming along very well! nice find.

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dauchande
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PostPosted: Sun Jul 31, 2011 3:04 am
Post subject: Re: Desertpir8's '92 535iM project *photos*

Nice looking machine, good to see there are still some people investing in the e34's around town.
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desertpir8
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PostPosted: Mon Aug 01, 2011 1:38 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Going to get this thread updated with a few hundred new photos of the project...

New Powerflex subframe bushings.


Here is the old subframe bushing, ready to be removed.<br>


Through combined use of a drill, sawzall, and prybars, the old bushing comes out. THis took about 15-20 minutes per side to get to this point.


Old bushing out. Ready for the new Powerflex subframe bushings.<br>


With a little of the provided silicone grease, the bushings slide into place pretty easily.


There we go. Then just put the stud back into place, bolt everything up and its finished.

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'62 M-B Unimog 404.114
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desertpir8
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PostPosted: Mon Aug 01, 2011 1:46 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Alright.. a few new photos for you all. I was planning on installing stainless brake lines and refinishing all the calipers today, but found out that my brake lines that I had received from FCP were the wrong ones. Will call them tomorrow to see what they can do. So, since I couldn't do that, I decided to try a little experiment with the wheels to see if I could keep them cleaner.

Might seem silly, but here's what I did. The back of my wheels were all kinds of ugly. Decided to try cleaning and polishing/waxing them to see if it would make them easier to clean. Here's what I started with:


Then used some of this.. (BTW, do NOT let this stuff stay on the surface long!) Awesome cleaner, but you have to be careful with it.


After cleaning and scrubbing, this is what it looked like:


Then comes some Meguiars cleaner/wax..


After waxing and buffing... Holy smokes, its shiny now! Those are some CLEAN M-systems! There is still some dust in/around/under the covers, but I figure that is going to be unavoidable.


My theory is that the waxed surface should help prevent brake dust from adhering to the wheels. I'll see how they hold up. It was very easy to do. Only took about 5 minutes per side.. and the wheels look like new now.

And now a few photos of them on the car...





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desertpir8
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PostPosted: Mon Aug 01, 2011 1:48 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Currently wrapping up a full weekend of work on the car. Working on wrapping up the following:

- New AKG Motorsports polyurethane rear trailing arm bushings.
- Drilled, tapped, and installed 4 grease zerk fittings to keep the new poly RTABs quiet.
- Stainless Steel Brake Lines all around.
- Complete cleaning and refinishing (gloss black) of all 4 calipers.
- Full brake fluid flush & change out to synthetic DOT4 fluid.

I've taken tons of photos. Will try to get them uploaded tonight for you all!

Ok.. photos!!

This was a huge undertaking. I hope you all enjoy the photos. I spent about 25 hours in the garage this weekend working on all this:

Started with the front calipers and lines on Friday night. Here's a before pic:


And after refinishing the caliper & installing stainless brake line:


Got the passenger side done:


Then Saturday morning, I moved to the rear and started disassembling the driver's side. This was going to be a big job, as I'll be refinishing the calipers, installing AKG Motorsports RTABs, and stainless brake lines.


And just like that.. rear trailing arm is out.. Wish it was that easy! Smile


Here's the rear trailing arm out of the car:


Bushings are removed.. more on how that was done later:


After a little powerwashing, the trailing arm almost looks new!



One thing I did while I had the trailing arm out, is to drill and fit grease zerk fittings to be able to grease the poly bushings if/when they start getting noisy:


Here's the new bushings for this side:


And installed in the trailing arm:


Closeup:


The trailing arm gets reinstalled:


Some detail shots:




yes, i know the clip is missing.. hadnt installed it yet..

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desertpir8
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PostPosted: Mon Aug 01, 2011 1:50 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Moving to the passenger side rear. Here's a before shot:



Once the arm is removed, here's how you can remove the bushings with a Harbor Freight balljoint/Ujoint press and a sawzall:

First, press out the middle:


Then, using a large socket, press out the second steel sleeve. This socket is a 1 1/16" craftsman socket. It just fits inside the outer steel sleeve:


Second sleeve is removed:


Now continue pressing the socket all the way through:


Most of the bushing is now removed:


Next, make 2 cuts with the sawzall like so: This allows you to break the shell free of the trailing arm:


Then, with a chisel, you can break the shell free and tap it out:


And its out!


Next up, zerk fitting is installed:


Two zerk fittings installed:


Bushings installed.. and its ready to go back in:


And here we go.. Its back together:



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'62 M-B Unimog 404.114
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desertpir8
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PostPosted: Mon Aug 01, 2011 1:51 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Alright.. More photos from today's adventure.

I decided to tear the exhaust/driveshaft out to get the UUC EVO3 shifter installed. This is actually a much more involved installation that I was anticipating, but I ended up uncovering a few more things that need fixed on my car in the process.

So, here we go.. Got the exhaust and heat shield dropped off the car.


Gives me access to the driveshaft:


And what do I find? One center support bearing in dire need of replacement. The driveshaft has totally collapsed to the bottom of the CSB:



Next, the driveshaft comes out. I found that the CV on the rear of the driveshaft has slop in it. So, I think its time for a new driveshaft or to have it rebuilt. Sad



This photo shows the dead CSB pretty well:


Here's a shot of the original shifter:


UUC is going to build a DSSR to work with the e34 535i manual based off the measurements I give them. Here's the selector rod removed from the shifter assembly:



Center to center, the Selector Rod pins are 9 9/16" or ~243 mm



Now time to remove the old shifter:


It was SO worn out, that I just lifted up on it and the whole thing came out:


I think its dead..


That leaves me with the shifter mount.. time to remove it:


Here is the clip that must be removed to get the shifter mount out:


And its out!


Next up, remove the bushing out of the end:


And now install the UUC EVO3 shifter parts:




The rear bushing wasnt too bad, but I'm going to order a new one anyway:


After the mount gets installed, the shifter goes in:


I took the opportunity to install some polyurethane transmission mounts as well:


A shot from underneath.. I stock the selector rod back on there temporarily to see how it shifts. Shifts pretty nice, but I can't put it back together until I get the DSSR from UUC.



New Shiny:


And thats it for today. Now, I have to wait for the DSSR to be manufactured, wait for a new driveshaft to get here along with a few other new parts and it'll go back together.. Can't wait to drive the car. Its been weeks since I've driven it since its been in the garage being wrenched on for so long now.

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desertpir8
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PostPosted: Mon Aug 01, 2011 1:52 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Photos from today! Got the transmission out, got it mostly resealed, and also rebuilt the driveshaft tonight.

New 245mm UUC DSSR:



Heres the trans right after I pulled it out of the car:




The selector rod seal was definitely leaking:



Rear output seal looks like it might be leaking too:



And here it is after a bit of cleanup:






And on to replacing the transmission seals. Removed input shaft seal housing:


Seal removed:


New seal installed:


Input cover reinstalled. Make sure to use a very thin bead of sealant around it, as it must seal in the trans oil.



Next up is the selector rod seal. Removing the shift linkage fitting on the selector rod. First slide back the clip from around it:


Then push out the pin:


Yep, it was leaking.. check out the remains of the foam damper inside:


Old seal removed and new seal in place. The old seal was a PITA to remove. I highly recommend just pulling the transmission to replace it. Mine didnt want to come out and required use of a lot of different tools to finally remove it.


Heres what the foam bit is supposed to look like:


And reinstalled. Its amazing what a difference that little foam bit makes. I imagine its going to shift pretty nicely with that in there.



I tried to remove the output flange to R&R the output seal, but found that I didnt have the correct socket to do so. Will be picking up one tomorrow to get it done.

Getrag.



throwout bearing and arm greased and reinstalled. I didnt bother replacing any of it, as I'm going to be saving up for a single mass lightweight flywheel and performance clutch.


Test fit of the DSSR:

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PostPosted: Mon Aug 01, 2011 1:53 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Some pics of the clutch/flywheel:



Thinking I might want to pull this piece and reseal it. Looks like coolant might be seeping from around it:


Next up is the driveshaft.. Removed the old CSB and installed the new one. The old CSB bearing was pretty rusty!


New CSB installed.. getting ready to tighten up the securing bolt.



Tomorrow, I get to put it all back together.

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PostPosted: Mon Aug 01, 2011 1:53 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

As an update.. we got the rear seal replaced on the transmission and then got the transmission reinstalled under the car.

Started putting the shifter back together and found that the UUC DSSR that I was sent does not seem to fit the UUC EVO3 SSK. The spacers they supplied for the bearing on the shifter are about 0.075" too wide to fit into the opening of the DSSR. I'm gonna check it one more time to make sure the bearings haven't shifted in the end of the shifter, but I couldn't get it to assemble as-is. Will post up some photos in a bit. I got frustrated with it though and decided to call it a day, since a friend was coming over that needed some help working on her car.

UPDATE: Ok, went out and checked the shifter one more time.. there's no possible way the DSSR is going to fit unless I remove material off the shims or can get UUC to correct the issue.

Inner dimension of the end of the DSSR = 0.810"
Outer dimension of the shims/bearings installed on shifter = 0.884"
Outer dimension of the shims stacked together off of the shifter = 0.857"

The machined shims they supplied are too thick. Car is gonna be stuck in the garage until I can get this resolved.

Here are some photos from what little I got done today:
Transmission reseal complete and trans reinstalled:


Here's the problem with the UUC evo3 shifter and the DSSR I recieved from them. Definitely not gonna fit.


Some measurements I took:
bearings + shims/bearing adapters on SSK = 0.884"


Just the shims/bearing adapters removed from the SSK = 0.857"


Opening of the end of the DSSR = 0.810"


So, thats where I'm at. Can't do anything else until this gets fixed. Sad I really miss driving my car.

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'62 M-B Unimog 404.114


Last edited by desertpir8 on Mon Aug 01, 2011 2:39 pm; edited 1 time in total
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desertpir8
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PostPosted: Mon Aug 01, 2011 1:54 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Got some parts in the mail thanks to Kate at UUC. These are the correct inserts for the shifter I have:


Here they are compared to the ones that I had:



And that's what it needed.. shifter + DSSR installed. The 245mm DSSR fits perfectly.


DSSR clears the guibo nicely:


While I was there, I went ahead and used a little Right Stuff on the output shaft nut to seal up the end of the splines on the output shaft. Hopefully no more leak.


Shift boot and knob installed:


And there we have it.. that bit is done. Starting to go back together now.


Next, I got the driveshaft reinstalled as well as the heat shield.


Got the slave installed after this pic was taken.


And thats where I'm at as of tonight. Now just need to change the trans fluid and then get the exhaust and wheels installed and its back on the ground again. Might actually get to test drive it tomorrow night.

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desertpir8
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PostPosted: Mon Aug 01, 2011 1:55 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Car is now back on the road! Took it for a spin tonight.. OMG, the rear suspension is tight!!! The back of the car feels like its just planted on the road at all times. No slop side to side. Very precise in turns. Not much additional noise from the back of the car with the AKG Motorsports urethane RTABs. If any of you do this mod, I think you will all be very pleased.

One thing I'm going to have to take care of tomorrow.. The Redline MT-90 I used in the trans doesn't seem to be working well. Feels like its catching teeth on mild/slow shifts, so I'm going to drain it tomorrow and install some Redline D4ATF and see how that works.

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PostPosted: Mon Aug 01, 2011 2:14 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Awesome!

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PostPosted: Mon Aug 01, 2011 2:26 pm
Post subject: Re: Desertpir8's '92 535iM project *photos*

Awesome work!

So is your camera the dirtiest thing in your garage? When doing my build and repair jobs I shy away from using my camera because I don't want to waste a perfectly good DSLR.

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