Too bad you are closer or else I could do the coding work for you. Good to hear everything wnt smoothly for you.First of all thanks to Jared for this thread. I did the conversion on my wife's 325iT and the result was pretty good. Her words were: "It's like the car is happy now!" Indeed it is, and also quicker, with more positive feedback, and more fun to drive.
So some good things and what I learned:
Order your transmission first. I got my transmission, Drive shaft, and flywheel from Bavarian Auto Recycling delivered to Canada for less than a $1,000. I also ordered parts I didn't need like the shift pins as my transmission was an updated one post 2003 I guess. So I would have saved some $ if I had ordered the transmission first.
I ordered my parts from Pelican Parts, in retrospect I could have ordered a bunch of this from Bavarian and saved some $.
The clutch and SSK were from Turner. The SSK is the most expensive part but the shifting feel is excellent - notchy/precise, short and not too much effort!
Assembly was straight forward forward following the instructions contained here. The biggest mistake I made was not thoroughly prewiring the reverse lights. I have them wired but not connected to the transmission. I do not have the connector that plugs into the transmission and have not yet been able to source one. Trying to wire it when the transmission is in is difficult
What issues to I have?
1) PDC (Park Distance control) is not yet operative but I do not think this will be an issue. I have the reverse signal figured out once I get the connector. PDC should just require review of the wiring diagrams to find out where the signal is supposed to go.
2) Cruise works but the clutch does not disengage the cruise. It is wired but the car is not yet coded (more on that below)
3) After turning off the car it takes about 30 seconds for it to reset and respond to it being turned on. In other words if you stall you can't just crank it, you need to wait first. This is a safety issue, and one I expected to be corrected when recoded.
4) The big issue is that the Dealer, actually BMW Canada refused to recode the car. I had checked with the dealer prior to doing the conversion, and although they hadn't done this they felt they could reload the program. So even though they quoted $650, I took it in to have it done. Part of the cost was the Tech wanted to check my wiring first. So he did that, confirmed it was correct, sent the "PUMA" request to BMW for recompiled coding and was told that "due to potential Federal compliance and safety issues" they would not provide a recompiled program as it did not have a correct wiring harness. Oops - still cost me $135 for the "diagnosis".
The recoding is not essential, but I would like to get it done. There is an independent that the parts guys at the dealership recommended, but I haven't made contact yet. My normal mechanic has suggested some "reprogramming sources" where I send them my DME or ECU or whatever is necessary. More investigation is needed.
So I have added this post to give thanks to the previous posters for their guidance and add my small bit to the knowledge base. The conversion was initiated because of a faulty Automatic transmission that was increasingly putting the car into limp mode, and a desire to put a tow bar on the car. (I installed a Witter yesterday). This is effectively our utility vehicle and we expect to keep it a long time. With the manual and with the tow bar it meant we didn't need to look at a new or newer SUV or pickup. I am probably a little underwater on the car value wise, but the best solution for that is use.
Would I do this again? Absolutely. The car is now a joy to drive, and feels much stronger.