Another 5 Speed Conversion Coming

[jaymanek]

Well I picked up Ed's last getrag 265 gearbox yesterday and Mark Bull is sending me the conversion kit this week.

Im going through a list of things to order so I can get started asap..

So watch this space, ill update with pics etc as I go along.

These guys have been extremely helpful, they know the process inside out!

[Garry]

Hi Jaymanek,

Am in exactly the same boat at the moment.  Have a Getrag gear box, waiting on parts from Mark and have on order the BMW parts and a mechanic on standby to help in the conversion as I don't feel confident enough to do it all by myself.

Are you planning to keep the mechanical speedo drive and convert the Getrag to mechanical output?  I decided to go that way but it is quite pricy for the parts to do the mech drive conversion.

We should be able to compare notes!!

Garry

[jaymanek]

Hi Garry,

The gearbox from Ed has already undergone the conversion, so all i need is a new speedo cable which im waiting on.

Ill keep the thread up to date..

The biggest challenge ive had so far is finding a clutch for the car! Im spending 350EUR and for all i know my clutch may well be new...

I want to get all the parts together and tackle this in a weekend. It doesnt look too difficult, the only stumbling blocks I see is if I miss any parts needed.

[jaymanek]

So I have ready:

- Getrag Gearbox with mechanical speedo conversion and full rebuild by all gears in Nottingham
- Shortened & Modified Drive Shaft by Propshaft Services in Feltham
- All 3 parts for New Clutch - From Mercedes Main Dealer
- Conversion Kit from Mark
- Speedo Cable from Speedy Cables in Wales
- Propshaft Dount From Euro Car Parts
- Four Nuts with Countersink Heads and matching Bolts

Today I was prepping the box. I cut off the excess using my fine saw and dremel and ive attached the brackets for the shift mechanism.

Hopefully I have all the parts to do the conversion, so ill get going tomorrow afternoon.

Pictures to come.

[jaymanek]

Hi All,

Right im done!

The parts you need I have listed above. Thanks again Ed and Mark.. you have been invaluable!

A good selection of nuts, bolts and washers is also needed.

So the process to convert from 4 to 5 speed manual is as follows (from memory):

- Cut off the two upper rear mounts on Getrag Gearbox (Pictures of this are on Marks thread) and smooth off
- Cut off the sleeve around Input Shaft on Getrag
- Slide over Marks Input Shaft Spacer with a bit of Loctite, or if tight already then just tap on after heating up with chamfered end facing into engine
- Install the two L shaped brackets on the top of the gearbox for the shift rods included in Marks kit (see pictures)
- Remove current gearbox
- Change Clutch for a new one if you dont know the history of it
- Remove Bell Housing from Old Geabox
- Countersink holes as shown in pictures below and you will need countersink screws and nuts
- Install stepper ring from Marks kit onto back of bell housing
- Install the studs onto each side of the Spacer in marks kit
- Install this spacer onto Getrag
- Push on bell housing and tighten up
- Install Gearbox & Shortened Propshaft with BMW Mounts and Marks Mounting Bracket (which i painted in several coats of hammerite)
- Mark supplied spacer plates for the gearbox mount but i didnt use these
- Install new speedo cable (part number is 211556 for a LHD car)
- Install Reverse Light Wires
- Fill with 90/90 Gear Oil

Note the lenght of shortened propshaft is 1195-1200 mm from flat face of flang at diff to spline at gearbox.
I did not butcher mine, instead got a second hand one from  a saloon and had both pieces shortened.

Other Info:
- Part number of BMW Gearbox Mounts - 23711175732 x 2
- Speedo Cable from Speedy Cables in Wales

Not sure if I missed anything, if anyone needs more info, dont hesitate to ask!

[Garry]

Well done, and how does it drive? Also what is your rear end ratio?

Great photos and instructions for me to work with in the next few weeks to do mine.

Garry

[jaymanek]

Hi, it drives exactly like before, just with a fifth gear to calm things at high speed.

Im not sure what diff ratio is, whatever was standard on a 280 manual?

I just need to make a small cut in the transmission tunnel as it is just slightly touching behind the handbrake lever.

[Garry]

 I changed my standard 4.08 rear axle to a 3.46 a couple of year ago but kept the old axle. It will be interesting to see how it goes initially with the 3.46.  I may end up with too low revs and a lack of torque for 5th or maybe just a true over drive in the modern sense to be used above 55+mph

[Franz W]

Hallo,

i have also a 5-speed conversion set from E. Mander and his friend, but did not start the conversion till now, because of engine problems in the winter.
Would be interesting for me to know, if the speedometer shows the right speed with the Getrag transmission, or if not , how much is the difference.

Best regards Franz

[jaymanek]

Something i never thought about!

my gearbox has been rebuilt here so im sure its set up correctly. I will check with a GPS device and report back.

The new cable has made my speedo much more smooth though!