My BMW E46 330i - The stuff of dreams

[Zound]

Finally put the car on the rollers, for the first time!
Thanks FR & R Tuning for the Dyno night.

Here's the graph :

 

[Zound]

Front brake pads replaced. The previous owner /mechanic decided to cut the old brake pad wear sensor off instead of just replacing the (cheap) component.

Decided to go with Meyle HD because I have only had positive experiences with their products and associated quality. Will provide a review after a couple months.

Also did a full brake and clutch fluid flush.

 

[Zound]

As part of the Vehicle engineering module at the University of Pretoria, I was privileged enough to experience an outing to the Gerotek test facilities in Pretoria.

We got to have fun on the skidpan and have a couple laps around the handling track. This was the first time my car has seen track action and what a fantastic experience. The skidpan was just a bunch of laughs with my car as it is absurdly tail-happy. Countless 360's and attempts at holding a drift.

The handling track was the highlight of the day where I did about 4 or 5 hot laps with my car. The cars handling was above my expectations and I was really impressed with the cars ability to change direction and the braking. So with that in mind I think the Meyle HD pads are doing very well and I wouldn't hesitate to take my car to a track day with the current braking performance.

I am thoroughly enjoying this E46 330i:blowheart:

 

[Dewald Basson]

Zound you must really join us next we head out to the track....




Ps. I am going to Zwartkops tomorrow

 

[Zound]

The time has finally come to do a clutch and flywheel change! Write-up to follow, so stay tuned!

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So my clutch has been slipping for at least the past 6 months, every single gear and right at around 2000RPM to 2500RPM where the max torque starts rolling in. Additionally, the dual mass flywheel has been worn out since I purchased the car owing to the infamous vibrations and shudder on take-off unless you ride the clutch at 3000RPM. So a much-needed clutch and flywheel change has been on the cards for a while now.

Also, I've been wanting to sort out the slop in my shifter and the detent pins which have failed and thus there is no spring resistance in the 5th gear plane and my reverse gear requires extraordinary human force to engage.

And another concern, I've had a small oil leak at the bell housing and thus I expect the rear-main seal to be shot and need replacement.

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First off, here's the vehicle ramps I built with some of the stuff I had lying around.

And finally in the garage with the rear jacked up and on axle stands:

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Here's the workbench all cleared up:

The new OEM clutch (Self-Adjusting) and flywheel (Dual-Mass):

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So exhaust out, prop-shaft and centre bearing disconnected, and onto the transmission removal!

 

[VictorMike]

Nice! Your car and garage is awesome!

 

[sash]

nice setup , is that a single or double garage.

 

[Zound]

Nice! Your car and garage is awesome!

Thanks man, the garage is getting quite the cleanup at the moment.

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nice setup , is that a single or double garage.

4 car garage :rollsmile:

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Transmission out:

Clutch and flywheel out:

 

[DINODENASH]

Wow nice work bro

 

[Zound]

Did some cleaning today:

 

[ChefDJ]

So much dedication to this car. She's a stunner. Well done bud :clapper:

 

[Charlie Brown]

Awesome DIY, props to you and you pops for taking this on, it's not easy.

I'm assuming that you didn't pay the agents the R15k for their DMF ? Their clutch isn't badly priced, the DMF is just insanely priced !!

I just had mine done and would suggest that you look the the following too;

New slave cylinder for the clutch.
The oring on your selector needs replacing.
There are a herd of plastic clips / bushings / washers etc linked to the linkage that should be replaced too - all addd to the slop, the 'knuckle' is he main cause however.
Guibo /Flex disc & gearbox mounts - check & replace if necessary.

Keep us updated and add more pics.

 

[Zound]

Awesome DIY, props to you and you pops for taking this on, it's not easy.

I'm assuming that you didn't pay the agents the R15k for their DMF ? Their clutch isn't badly priced, the DMF is just insanely priced !!

I just had mine done and would suggest that you look the the following too;

New slave cylinder for the clutch.
The oring on your selector needs replacing.
There are a herd of plastic clips / bushings / washers etc linked to the linkage that should be replaced too - all addd to the slop, the 'knuckle' is he main cause however.
Guibo /Flex disc & gearbox mounts - check & replace if necessary.

Keep us updated and add more pics.

Thanks!

The clutch slave cylinder I replaced about a year ago.
I've done the selector rod seal (it was leaking) now with the clutch change.
Gearbox mounts were completely sheared so new ones installed.

The best deal on parts was obtained from Goldwagen for the flywheel (About 4.5k) and Bemows for the clutch kit (About 2.8k).

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So rear main seal and gasket have been replaced (got the parts from Imcomex). In the picture below you can see the selector rod seal, shifter bushing and a new cabin air filter:=):

Here are the revised detent pins for the transmission:

And two of them that I removed:

We also tackled the 5th gear and reverse plane pin components. We removed the pistons and then honed the bushing surface with some fine sandpaper while in the gearbox. The process is explained and detailed here: http://www.unofficialbmw.com/phpBB/viewtopic.php?t=33179
Another good DIY: http://webspace.ringling.edu/~dplassma/bmw_diy/shift_pins/shift_pins.html

Below you can see the caps retaining the detent pin sets and then followed by the side of the transmission which house the 5th and reverse plane piston sets:

Now, finally a pic of the flywheel and clutch installed:

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Some last photos of all the reassembly:

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First test drive review: The result in the shifter is incredible. There is a lot less play in the shifter, there is no more hard notchiness and reverse is a lot easier to engage now! The 5th gear plane spring action is working perfectly and the entire shifting experience feels superb. The vibration, flywheel chatter and shudder on take off has completely vanished with the new DMF and no more slipping of the clutch in the torque band. Take-off is now smooth, quiet and effortless.

The process was expectedly unenjoyable (read a real pain in the a$$), but I'm very happy with the results.

Viva la 330i !!!

 

[Zound]

Finally driving my car at sea level, here in Ballito KZN. Wow, quite a substantial difference! The power feels rather brutish. Haven't revved it out or abused it yet because I'm still wearing in the new clutch and flywheel. Quite a lot of fun though, really feeling like a child with a new toy :rollsmile:

 

[Kish2604]

Well done on your efforts Bud... A job well done and now you can enjoy the fruits of your Labour...

Sent from my SM-G920F using Tapatalk

 

[kilotango]

was the main seal shot then? you mentioned an oil leak initially?

nice work btw :coolShake:

 

[Francoisjl]

Reading through the thread I wish the wife rather bought me a 46er, I know they down on power to the e90's but good golly they are sweet looking cars and bunch of fun (thinking back to the brother in-law 320d 46er) great thread and the details are awesome.

Keep it up bud

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[Zound]

So this weekend I replaced the valve cover gasket.

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[Tinuva]

Damn this car gets a lot of love. I like it every time you post an update on this thread. Whats the mileage on this one now?

 

[Zound]

She's covered just over 295 000 km's

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