1976 BMW Motor Replacement - BoJo

[BeMyWay]

Thank you for all your help.

 

Yeah, I thought about side drafts,,,but, I'm mosly daily driving.  After I get it running, lets see if I want a little more noise and hopefully MoPower!

[BeMyWay]

The story continues...Lets talk clutch.  

Well, some time ago I was whining about not being able to shift into gear.  

The car had set for sometime, because I own multiple old cars and have children who drive old cars, etc, and i was working on these old cars and not driving my old car! 

I did the following:

• I drove the car at all sorts of speeds and perform every gyration of shifting, braking, clutching and nothing worked.  During all this crazy driving, I did find out that my rear brakes were incorrectly adjusted!!!
• I finally pulled the engine and transmission and the following is is what i found:

 

- Das BoJo: 1976 stock (as much as can be for a 47 y.o. car) with 14" MSW...She need a wash, wax and paint job! 

 

BoJo's motivator has been removed...stock with emissions.

 

 

 

The evidence of something gone wrong...looks like fabric stuck on the pressure plate...Hmmm

 

A close examination shows it to be stuffing fabric from my lawn chair...I saw a hole in one of the pillows and wondered where the critter nest was being created...Now I know where!   

 

Here is the picture of the living quarters

 

I had to use a rubber mallet to break the seal between the flywheel-clutch plate-pressure plate...these were never going to release from each other by driving fast and/or then braking.

 

The clutch and pressure plates both look fairly new.  They are the 215 mm.

 

Pressure plate was branded by the clutch plate.

 

Finally, the glue to this mystery.  It is still a mystery as to where did all this moisture come from to cause this issue. I'm not sure what happen to the little fella who moved into my bell housing...probably waiting for the new assembly to be installed...LOL

 

Just a shot of the messsy engine bay...somebody needs to clean this up!

 

My lessons learned...never let your favorite car sit too long and always check your rear brakes

 

To add insult to injury,  while trying all these braking antics, my rear shoes stuck in an expanded position and would not release...gotta change out one of the rear brake wheel cylinder.  

 

My car came from the SF bay area which might explain the pressure plate surface rust...BUT, the varment was a local critter.  Also, this car was under a carport most of the time...

 

More to come.

Edited December 30, 2023 by BeMyWay

[Son of Marty]

Your trans is from a e21 most likely it for sure not a 02 trans. On the e21 trans the clutch slave needs to be mounted with the bleed screw pointing down many have been installed with the bleeder pointing up and that way you'll never get it bleed right and the clutch will not fully disengage.

[BeMyWay]

Marty,  you are correct, I do have a 5-spd from an e21.

 

I bought all new hydraulics pieces (MC, SC, and braded steel line) and installed the new slave cylinder as you noted and bled that system for all it was worth!   

 

Howwever, because it was stuck, the assembly never released...The new clutch assembly feel solid. 

 

Thank you for the advice.

[BeMyWay]

Here is a picture of my installed slave cylinder .

 

 

That is one seriously tight fit to get to the top bolt when it is installed in the 2002!!!!  

 

Anyone have any alternatives on how to reach this bolt? 

 

I finally cut a small hole into my tunnel to reach this bolt...I'm going to make a bigger hole and install a plate over it.

 

 

Edited December 31, 2023 by BeMyWay

[SydneyTii]

We have the best anti rodent solutions in Australia….. but jeez they give you a nasty shock when you open the hood… at least these ones aren’t venomous!

[BeMyWay]

I don't like Snakes! 

I can deal with the fuzzy ones...I gotta make sure I drive more! 

Edited January 3 by BeMyWay

[SydneyTii]

Lol yeah I hear you, not my car thankfully, we have a few red belly black snakes and brown snakes around where I live, pretty venomous to say the least, thankfully my cat is a great “ratter” so the snakes have nothing to eat in my yard!!

[BeMyWay]

Okay, I'm back...

 

I have a few pictures of my flywheel/clutch assembly. 

As I discussed earlier...the instigator of having to remove the original m10 engine was the clutch would not engage and resulted in making the decision to just remove the engine/transmission.

 

After removing the engine, I found the clutch culprit...see above pictures.   

I found it had a 215mm flywheel/clutch assembly...although stuck together!

 

For some reason, which I can't rememeber at the moment, I decided to go down the 228mm rabbit hole.
 

Following are some picture of the new 228mm flywheel/clutch assembly on the top row.

Bottom row shows the 215mm pressure plate and clutch plate and a project 228mm flywheel.

 

Follwing is the backside of the 228mm flywheel which was lighten when I purchased it.  Also, I am showing a stock 228mm flywheel for comparsion.

 

On the following pictures you can see where the material was removed...I am told the flywheel material removal was performed at IE.

 

 

 

 

 

Also, pictures of the throwout bearing.  

 

 

 

My hope is, I will not have a problem with the throwout bearing's length because the 228 vs 215 flywheel/clutch assemblies' overall height difference.   We will see if there are any issues.  I think I have figured everything out...

 

 

If anyone has any advice on the proper throwout bearing to use with this 228mm flywheel/clutch assembly, will you please let me know. 

 

I'm hoping in the next few weeks to get the engine and transmission all reassembled and back into the car.   

 

I am sure I will need loads of help from you all as I move forward with this assembly.

 

Take care.

Edited January 8 by BeMyWay

[jimk]

Clutch release bearings are listed with an "H" dimension.  The one you have is correct for the 245 5 speed and the "H" dimension is 30 mm from the top of the 2 ears where the operating arm touches and the face of the bearing that touches the pressure plate.

[BeMyWay]

I'm jumping all over the place at the moment. 

 

Right now I am searching for shifter refurbishing parts.

 

My real problems are determining what shifter parts do I have. 

 

I have the stock shifter assembly but there were a few modifications made by the PO to make it work with the 5spd. 

 

Shorten shift plate:

 

 

 

 

Shifter disassembled:

 

 

Selector rod:

 

 

Selector rod joint:

 

 

• Is the shifter assembly BELOW from an early or late shifter assembly ?
• 

 

 

I need advice on the following:

• Are all my shifter parts from an early or late 2002 4spd ?  
• Does my shifter use a 2002 4spd shifter rebuild kit?
• Any changes would you suggest I make before reinstallation?

 

As always, thanks for any advice.

a

 

Edited January 12 by BeMyWay

[2002iii]

That looks like late shifter  platform it's probably from the an e21. The regular late shifer rebuild kit should  have everything you will need.

[Son of Marty]

It's a late shifter yes a 4 speed shifter rebuild will do also replace the shifter to trans mounting blocks.

[BeMyWay]

Thank you.  I will be ordering everything asap.

[Dudeland]

On 1/8/2024 at 12:18 AM, BeMyWay said:

Okay, I'm back...

 

I have a few pictures of my flywheel/clutch assembly. 

As I discussed earlier...the instigator of having to remove the original m10 engine was the clutch would not engage and resulted in making the decision to just remove the engine/transmission.

 

After removing the engine, I found the clutch culprit...see above pictures.   

I found it had a 215mm flywheel/clutch assembly...although stuck together!

 

For some reason, which I can't rememeber at the moment, I decided to go down the 228mm rabbit hole.
 

Following are some picture of the new 228mm flywheel/clutch assembly on the top row.

Bottom row shows the 215mm pressure plate and clutch plate and a project 228mm flywheel.

 

Follwing is the backside of the 228mm flywheel which was lighten when I purchased it.  Also, I am showing a stock 228mm flywheel for comparsion.

 

On the following pictures you can see where the material was removed...I am told the flywheel material removal was performed at IE.

 

 

 

 

 

Also, pictures of the throwout bearing.  

 

 

 

My hope is, I will not have a problem with the throwout bearing's length because the 228 vs 215 flywheel/clutch assemblies' overall height difference.   We will see if there are any issues.  I think I have figured everything out...

 

 

If anyone has any advice on the proper throwout bearing to use with this 228mm flywheel/clutch assembly, will you please let me know. 

 

I'm hoping in the next few weeks to get the engine and transmission all reassembled and back into the car.   

 

I am sure I will need loads of help from you all as I move forward with this assembly.

 

Take care.

Did you mange to get a final weight of the lightened flywheel.?