E46 Fanatics Forum banner
1 - 20 of 20 Posts

·
Premium Member
Joined
·
7,502 Posts
Discussion Starter · #1 · (Edited)
After about 1.5 year with the DCT Project, I decided to switch platforms. DCT is out along with the transmission wiring and the controller. Reasons many but not part of this thread.

In its place, we're installing a ZF 8HP70z automatic transmission from the F30 330d series. A very capable, 8-speed transmission, that can handle loads of torque, that will be paired with a different control unit this time from TurboLamik. I will emfasize on the electronics modifications on this thread as well, along with the mechanical bits.

For this conversion, I will be using the following:

1. Adapter plate to allow this gearbox to bolt to the M54 block, as the starter is lower/left side instead of upper/right (sort of mirrored)
2. Custom or OEM mix'n'match driveshaft
3. Custom or OEM gearbox crossmember
4. Turbolamik TCU with MS43 canbus integration & individual drive mode programs
5. N55 6-bolt Flexplate (my crankshaft is 6-bolt pattern so got to use this one)
6. N57N torque converter (comes with the gearbox thankfully)
7. F82 M4 Joystick
8. E46 M3 paddles
9. Custom IKE integrated OLED display for gearbox info
10. Milspec wiring with proper connectors
11. Prototype 8HP billet aluminum oil pan
12. Setrab 25-row oil cooler
13. Davies, Craig 12" cooler fan with thermostat
14. Custom PCB board for 8HP Mechatronics modification
15. Oil Seals & Gaskets

At the moment I am waiting delivery of the gearbox. Once received and verified non-damaged, I will go ahead with the rest of the parts.

Gearbox:
Vehicle Motor vehicle Automotive exterior Gas Auto part


Automotive lighting Grille Hood Motor vehicle Automotive design


Watch Automotive tire Automotive lighting Tire Rim


Crank on my engine:
Tire Wheel Automotive tire Motor vehicle Automotive design
 

·
Registered
2004 E46 325i Touring 5-speed maunual
Joined
·
18 Posts
Wow, really sweet conversion! definitely gonna follow this. What's the reason you're ditching the DCT transmission? Cant you get it to shift like a factory fitted DCT car?
 

·
Premium Member
Joined
·
7,502 Posts
Discussion Starter · #4 ·
Can't trust the controller to provide reliable operation, especially when plagued with bugs and inconsistencies. Not my cup of tea, so moving to a proven-that-actually-works project. I'll post my whole experience in the DCT thread at some later point after I review it with a legal team.

Let's keep this thread 8HP only though.. Planning to order the adaptor plate and see what needs to be adjusted before going in the car. Thankfully I've got a spare engine to test everything.
 

·
Premium Member
Joined
·
7,502 Posts
Discussion Starter · #7 ·
Ordered a bunch of stuff:
1. All o-rings and seals
2. Oil pan with filter and new bolts

Old oil pan out, getting ready to remove the mechatronics unit. The tank above is oil pressure accumulator from what I read, to store presurized oil for cars with start/stop feature.
Motor vehicle Rectangle Gas Wood Automotive exterior
 

·
Premium Member
Joined
·
7,502 Posts
Discussion Starter · #9 ·

·
Premium Member
Joined
·
7,502 Posts
Discussion Starter · #10 ·
Followed the TIS instructions to remove valvebody/TCM from the gearbox and now getting ready to solder the new PCB.
Motor vehicle Automotive exterior Automotive lighting Wood Gas


Motor vehicle Gas Font Machine Auto part


World Toy Engineering Space Wood


Auto part Engineering Gas Machine Metal


Although all bolts will be replaced, good to sort them
Paint Wood Bucket Automotive tire Wheel


Motor vehicle Gas Machine Auto part Nut


Dremeling the 4 plastic welded rivets to separate TCU unit
Wood Watch Automotive tire Font Bumper


Shoe Textile Automotive tire Wood Asphalt


Exposed (almost)
Circuit component Passive circuit component Hardware programmer Electrical wiring Computer hardware


Cutting time:
Electrician Finger Safety glove Engineering Gas
 

·
Premium Member
Joined
·
7,502 Posts
Discussion Starter · #11 ·
Marking with blue, the max cutting depth (1.4mm)
Gas Machine Auto part Engineering Metal


Here it is...
Circuit component Gas Machine Auto part Engineering


Using a knife to cut all connections
Motor vehicle Hood Automotive lighting Automotive exterior Gas


Motor vehicle Electrical wiring Circuit component Engineering Computer hardware


After cleanup - left that pcb in place as it's glued
Circuit component Passive circuit component Electronic engineering Electrical wiring Engineering


Test fit of the new PCB, that will allow the aftermarket gearbox controller to... control this gearbox:
Circuit component Passive circuit component Computer hardware Electronic instrument Electronic engineering


Next steps: Soldering / Epoxy-Sealing / Reinstall
 

·
Registered
'02 525i Touring, ZF 5spd, VF supercharged.
Joined
·
17 Posts
Well, I was here for the DCT thread, and now I'm here for this. Have already learned a bit, excited to see the rest.
 

·
Premium Member
Joined
·
7,502 Posts
Discussion Starter · #19 ·
Wiring Weekend
TCU mounting position once clutch departs
Automotive tire Motor vehicle Automotive design Grey Trunk


Finger Thumb Electrical wiring Cable Engineering


Motor vehicle Automotive tire Vehicle door Hood Automotive lighting


Connected:
+12v straight from battery positive with 20A fuse
Ignition switched from below steering wheel (used as signal only)
Handbrake signal
Canbus signal from the twisted pair going to the instrument cluster
Reverse signal
Aux fan signal
Screen & Program selector
Tucked the wiring loom for the gearbox around the shifter area till the installation day
 

·
Premium Member
Joined
·
7,502 Posts
Discussion Starter · #20 ·
Flexplate, from N57N (converted to 6-bolt pattern for my unique crank)
Crankset Automotive tire Gear Bicycle part Rim


Adapter plate:
Bicycle part Crankset Rim Font Bicycle drivetrain part


Some "trimming" needed
Helmet Cutting mat Personal protective equipment Machine Circle


Comparing stock e46 bellhousing pattern with the adapter plate
Helmet Motor vehicle Automotive tire Gas Auto part

Automotive tire Font Rim Art Bicycle part


The E46 starter teeth seem to mesh fine
Wheel Crankset Automotive tire Gear Bicycle part


Run out of grinding disks, so expect to finish in a day
Automotive tire Motor vehicle Wood Bumper Automotive exterior
 
1 - 20 of 20 Posts
Top