This entry is copied from BMWclubMalaysia forum for backup purpose
Hello,
I’m documenting an undergoing project to convert my 2002 E46 318i N42 CKD from auto to manual.
History
Since early October 2011, after rempit session from Penang to Singapore the car transmission started to give warning on the way back. Warning will reset after restarting but would appear again after aggresive driving. There is knocking sound underneath the car (please see video) and gear change is now different. Visiting mechanic he said that gearbox need fixing and would cost quite a sum.
Never realizing this would happen to me, stumped for a day or two then finally accepted reality. So it’s either fixing it up or converting to manual. Decided to go for manual..
Parts searching started : contacted local supplier, and forumer but end up importing the part. Parts ordered and arrived on Feb 28.
Hope this thread would help me and/or anybody
References
http://forum.e46fanatics.com/showthread.php?t=659314
http://forum.e46fanatics.com/showthread.php?t=396320
http://forum.e46fanatics.com/showthread.php?t=855303
http://forum.e46fanatics.com/showthread.php?t=889867
Knocking from underneath the car
EGS/TCU – GS20 error
E R R O R M E M O R Y R E P O R T ------------------------------------- Date: 10/22/11 12:07:56 ECU: GS20 JobStatus: OKAY Variant: GS20 ------------------------------------------------------------- RESULT: 2 errors in error memory ! ------------------------------------------------------------- 146 CAN Moment interface Error frequency : 2 Logistic counter: 16 Error occured 1. times at: km value 135600.00 km Changing gear 1.00 0/1 Last change: implausible 76.00 0-n Engine speed 832.00 rpm Throttle-valve angle 0.00 % Error occured 2. times at: km value 135600.00 km Changing gear 1.00 0/1 Last change: implausible 76.00 0-n Engine speed 864.00 rpm Throttle-valve angle 0.00 % General error Sporadic error ------------------------------------------------------------- 48 Torque Converter Clutch - too much slip Error frequency : 6 Logistic counter: 5 Error occured 1. times at: km value 137030.00 km Gear 160.00 - Gearbox Oil Temperature 111.00 degrees C SV 1 0.00 0/1 SV 2 0.00 0/1 SV 3 0.00 0/1 TC-clutch closed 1.00 0/1 SV Shift-Lock 0.00 0/1 Brake operated 0.00 0/1 Error occured 2. times at: km value 137070.00 km Gear 160.00 - Gearbox Oil Temperature 108.00 degrees C SV 1 0.00 0/1 SV 2 0.00 0/1 SV 3 0.00 0/1 TC-clutch closed 1.00 0/1 SV Shift-Lock 0.00 0/1 Brake operated 0.00 0/1 Error occured 3. times at: km value 137430.00 km Gear 160.00 - Gearbox Oil Temperature 101.00 degrees C SV 1 0.00 0/1 SV 2 0.00 0/1 SV 3 0.00 0/1 TC-clutch closed 1.00 0/1 SV Shift-Lock 0.00 0/1 Brake operated 0.00 0/1 Blocked open Sporadic error =============================================================
Car has been resting well..
Parts at its origin location
Parts here – drive shaft
transmission
other stuff and clutch line
unwrapped
knob
shifter
dmf flywheel and sac clutch set
pedal
transmission support
exhaust support and boot
Getrag 220
Manual trans fluid is also for life
friction plate doesn’t have much life left
Release bearing renewed with sachs replacement acquired from Ban Huat Chan
around the house
Pedal work
Started with pedal swap before trans swap.
remove the trim panel above the pedal and found the gong speaker, front
rear of gong speaker
removal of OBD flap is not really necessary
to cut according the line
not a million dollar work
the ews 3
what it looks like under there
finding the hole for clutch master cylinder feed from brake fluid reservoir
found it
brake reservoir nipple to cut, ouch!
brake pedal assembly removed
auto or manual, pedal set side by side. The bracket of both are the same except for the extra and differently shaped pedal
installed
master/input clutch cylinder hose ready
before (single big brake pedal)
after (clutch and brake pedal)
auto trans with three pedal 
Installation
the car carried its own conversion parts
arrives at location for transplant
dismantling begun
auto and manual drive shaft difference, the shorter one is for auto. note the different mounting point
auto transmission (autotragic) out
GM box
made in france
auto and manual box side by side
steptronic shifter from below
automatic shifter out
shifting bracket snap into place (part no 25111222015)
manual shifter in
we had a hard time finding a hole for the clutch line so we drew one. I consider this as the hardest part of the work
dual mass flywheel in place
McFir7 and Khairul putting the box in
transmision support difference, the one being held is for manual
manual box supported, note the different mounting point from auto
me and McFir7 working on the exhaust support
auto oil cooler line from radiator disconnected
to get the engine running pin 2 and 8 from egs have to be shorted since we no longer have the autobox. this applies to GM gearbox/system only
GM transmission connector pin numbering on the gearbox side
the car springs to life, the traction control, abs and brake is on due to my wheel speed sensor. airbag light is expected
the magic stick
it took us the whole day to do the swap with some hiccups along the way. experiencing the amount of work involved, it would take me a long time to finish if I can finish at all to DIY this. thanks to the boys of ZF auto, McFir7 and ramsing for advice on the phone.
the car feels much lighter and zippier now. I don’t really like the clutch pedal placement not being more to the left. One thing to do immediately is to get/make a noise dampener at the shifter as road and engine noise is a bit too much than before.
Programming
Since my NCS-Expert exploration, I am able to reprogram the cluster to think that the car is manual. As a result the transmission error icon disappeared. Read about NCS-Expert here http://www.bmwclubmalaysia.com/forum…2-E46-318i-CKD
There was an error during programming probably because the EGS module is still there, even after programming, there is an error log indicating a foreign device on the CAN bus.
Here is the change I did to KMB
Generated with NCS Dummy version 0.5.0.5 copyright © 2011 revtor software
Output : Trace Differences
Chassis : E46
Module : KMB_E46.C06
Trace file 1 : "C:\Documents and Settings\Administrator\Desktop\original\FSW_PSW_AKMB.TRC" (FSW/PSW)
Trace file 2 : "C:\Documents and Settings\Administrator\Desktop\exp\FSW_PSW_AKMB.MAN" (FSW/PSW)
Differences : Yes
1 2 ID FUNCTION KEYWORD FUNCTION KEYWORD TRANSLATION
ID PARAMETER KEYWORD PARAMETER KEYWORD TRANSLATION
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
055D KM_SERVICE_INTERVALL SERVICE INTERVAL DISTANCE
* 01CF 25.000_km 25000 kilometers
* 031F 6.000_km 6000 kilometers
0581 GETRIEBE_ANZEIGE_GANG TRANSMISSION GEAR INDICATION
* 0001 aktiv active
* 0002 nicht_aktiv not active
This is the INPA report on the cluster long time ago (when coding to enable OBC)
INPA report after coding IKE, manual transmission!
I was still surprised that the car can still run after the coding..
How the cluster not have the cog-of-death icon anymore
Coding is not yet complete because the EGS is still connected to the bus, the EWS need updating to not check for P/N status from EGS
04C0 PARK/NEUTRAL_EINGANG ENGINE START ONLY IN PARK OR NEUTRAL GEAR
* 0001 aktiv active
0002 nicht_aktiv not active
MK60 need to be set for manual
0588 GETRIEBE TRANSMISSION
01FF handschaltung manual transmission
* 0200 automatik automatic
0201 sequentiell_ag
0202 sequentiell_msport
Few weeks ago I’ve decided to program the car to manual properly after raya. I’m going to utilize the Autologic machine available at the friendly workshop in Gurney.
First is to wire the clutch switch. which was done on Aug 31st break
diagram from WDS. Input to DME would be pin 23 from connector X60004
the box
opened
the DME and connector
disconnected
pulled out
cropped
use the trusty cd drive audio cable to add connection
added
connected back
fish wire into cabin
the grey wire is the reverse switch to activate reverse camera, into the cabin
going to driver footwell there is a tube
fish to driver side
using this switch temporarily
before programming, clutch switch doesn’t register in DME
Programming day
disconnect EGS
Autologic interface
And done, we can see clutch switch input in DME
EGS is out
Happy driving all
Differential work
Right now the car has plenty of pulling power (torque) and losing top speed. This proves a diff change is necessary. Pictures below show the rev before and after conversion at the same speed.
Before, in D
After, in fifth
The clutch line is in the car. It is behind the air condition. There is a hole ready for clutch line to come out at left side.
The pictures are not loading
Yes, i’m moving the pictures to a new host since photobucket stopped supporting free 3rd party hosting
How much did it cost you? Im thinking of doing a conversion too, need to know where to buy the parts needed, and where to convert it