#WrenchEveryDay

Nathan Avots-SmithDay 19: I got the wagon up in the air for the first time! And discovered the difference between a lifetime California car (the 530i) and one that's spent good chunks of its life in places like Massachusetts and Seattle (the wagon).Was planning to remove the exhaust, but couldn't even get started; the four nuts that attach the exhaust to the manifold studs are super rusty. One broke off, which is fine, but the others wouldn't budge. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/BMW" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#BMW</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/E39" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E39</a>

Nathan Avots-SmithDay 18: I have a rebuilt, reassembled ZF5HP19 transmission! (Second ZF I've had my nose in this week—does that qualify me for some kind of certification?)I did use the tool my dad and I made, but not the way I expected to; I used them to support all of the stacked assemblies while I lifted the transmission case up and over them. Hey, it was kind of dumb, but it worked! Next up: prepping the wagon for engine/trans removal. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/BMW" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#BMW</a> <a href="https://weird.autos/tags/ZF" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#ZF</a> <a href="https://weird.autos/tags/TransmissionRebuild" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#TransmissionRebuild</a>

Nathan Avots-SmithWrenching today turned into a good news/bad news situation. Good news: I'm getting my money's worth out of my QuickJacks. Better news: I fixed my transmission! Replaced the solenoids, filter, and fluid, plus the plastic bits circled in the photo, which are a common failure point. These were almost certainly original, meaning 16 years and 226K miles old. Yikes!Bad news: the water pump crapped the bed half a mile into my test drive. Sigh. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a> <a href="https://weird.autos/tags/BMW" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#BMW</a> <a href="https://weird.autos/tags/E90" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E90</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a>

Nathan Avots-SmithDay 17: I may be on vacation, but I still did a little something to make transmission reassembly happen more easily when I get home—my dad helped me make this little "tool" to clamp to the oil pump/A/B/E/C clutch assemblies to get them into proper position, as seen in the YouTube screengrabs. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/TransmissionRebuild" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#TransmissionRebuild</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/ZF" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#ZF</a> <a href="https://weird.autos/tags/BMW" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#BMW</a> <a href="https://weird.autos/tags/E39" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E39</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 16: no photos today, but I finished replacing O-rings and friction discs and started reassembly, which is a pain in the rear. Got stuck on trying to get the last few assemblies in (they're supposed to go in as a unit) and ran out of daylight, so I'll have to re-strategize and come back to it. Silver lining: I have zero unaccounted-for parts. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/TransmissionRebuild" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#TransmissionRebuild</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/ZF" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#ZF</a> <a href="https://weird.autos/tags/BMW" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#BMW</a> <a href="https://weird.autos/tags/E39" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E39</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithClutch packs and ring gears and oil pumps, oh my! <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/TransmissionRebuild" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#TransmissionRebuild</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/ZF" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#ZF</a> <a href="https://weird.autos/tags/BMW" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#BMW</a> <a href="https://weird.autos/tags/E39" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E39</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 14: dismantling the transmission has begun. So far, I've removed the oil pan and the valve body. This is going to be a messy job; I run into more undrained ATF at every turn. I've also already unbolted the transmission oil pump, so unseating and removing that will be job one after lunch. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/TransmissionRebuild" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#TransmissionRebuild</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/BMW" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#BMW</a> <a href="https://weird.autos/tags/E39" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E39</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 13 (can we finally call it that? Yes we can!): I am comfortable with mechanical stuff, not so much with measuring and cutting and drilling handicraft-type stuff, so the part of my transmission rebuild I've been most intimidated by has been fabricating this "tool" to compress the springs inside the clutch drums. But I did it! I might need a longer central bolt, but that's an easy fix. Tomorrow I start dismantling the transmission. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 11: I don't have the patience, skills, or equipment to get old engine parts looking brand new again—nor do I particularly care to—but I did manage to get the oil pan cleaned up okay while I had it off today. The old gasket was crumbly and clearly leaking, so that was a good replacement. I also replaced the oil pump nut, notorious for backing itself off, with one wired onto the sprocket, and replaced the oil level and pressure sensors. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 10: I finally made a punchlist of my remaining work—52 steps, but I got through nine of them today. Can't get too cocky, tho; one of the steps is simply "rebuild transmission."Today's accomplishments included removing the intake manifold and replacing all of the crankcase vent system components. Also replaced the manifold and throttle body gaskets and the DISA (resonance intake) valve, then put it all back together. Oil pan next. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a> <a href="https://weird.autos/tags/E39" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E39</a> <a href="https://weird.autos/tags/M54" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#M54</a>

Nathan Avots-SmithDay 9: couple days off, but I got a little bit done today. Biggie was getting the engine off the hoist and onto the stand, which required removing the flywheel, which required buying an impact wrench. Probably a good investment in the long run, and now I can do the rear main seal while I'm at it.Broke a few more old plastic parts, only to discover that past me had already bought replacements. Past me is a pretty smart guy. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithNo real progress on the <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> today...it was one of those days where I kept getting thwarted in what I tried to accomplish. But, UPS did bring the two most important/expensive components for my transmission rebuild: a new oil pump, and a remanufactured torque converter. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 8: got the engine and transmission apart! Biggest pain was freeing the starter from the trans bell housing. Tomorrow I'll get the engine on a stand so I can start my refurbishing projects on it; when some more parts get here, I'll be doing a full transmission rebuild.I also moved the 530 across the street (by myself!) and the wagon back onto the driveway (not by myself!), so I won't get a ticket for street sweeping tomorrow. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a> <a href="https://weird.autos/tags/E39" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E39</a>

Nathan Avots-SmithDay 6: the engine and transmission are out of the 530i! They will both get some refurbishment in preparation for installation in the wagon, but first, I have a few more things to scavenge off the carcass of the 530 before sending it to Pick-N-Pull. Biggest thing is that 530s and 540s got bigger front brakes than 525s, so I'm pulling off the 530's caliper housings so I can upgrade the wagon. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/E39" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#E39</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 5: Today was the first day in what is forecasted to be a week of rain, but I can't let that stop me. So I used my balcony, the hood, a drop cloth, and four clamps to fashion a canopy.About an hour of work and I now have the engine and transmission ready to be removed. All the electrical, fuel lines, AC and power steering components (still closed), and motor mounts are disconnected. Here we go! <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 4: Continued progress this afternoon toward getting the engine and transmission removal-ready, but the only pictures I took were of the things I broke. Nothing like plastic that's spent 22 years in a hot engine compartment!Luckily, I've already bought a replacement for the oil separator hose (second pic), as I'll be redoing the CCV system while the engine's out, so I'm looking at about $45 for the other stuff, if I can't salvage it from the wagon. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 3: I got a late start, so not a ton to show today, but basically nothing is attached to the transmission anymore except for the engine. Plan originally was to remove the trans first, separate from the engine, but now I'm wondering if they can't come out as a unit. Something to investigate tonight.A neighborhood inspector came by to check on my handiwork; the verdict was inconclusive. And, I removed my tapes from the car—one of those is a 2024 release! <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithA little more progress this afternoon. I removed the Sport steering wheel and auto-dimming rear view mirror, both of which I'll use in the wagon, and the Euro-spec center console armrest/bin, which I'm on the fence about.I also removed the radiator, cooling fans, shrouds, and a bit of other stuff from the front end, and encountered my first breakage—the fan clutch pulley was just no match for my brawn. Same part is on the wagon, so no biggie. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithDay 2: the exhaust came out surprisingly quickly and easily. The M54B25 and M54B30 use slightly different exhausts, so this will be going in the wagon, even though the downward pointed exhaust tip is sedan-specific. Might have to fix that sometime.It was still early, so I also removed the seats as a last task before disconnecting the battery for good. I was rewarded by finding a $20 bill under the passenger floor mat! More after lunch. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

Nathan Avots-SmithWith my QuickJack frame extenders here and setup complete, dismantling of the 530i is officially underway. The amount of work space underneath is positively decadent. Started simple, draining the oil, transmission fluid, and coolant. I also removed the rear sway bar, and the bumper cover and headlights to start breaking down the front end to ease engine removal. Tomorrow's project: removing the exhaust. <a href="https://weird.autos/tags/WeirdCarMastodon" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WeirdCarMastodon</a> <a href="https://weird.autos/tags/DIY" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#DIY</a> <a href="https://weird.autos/tags/EngineSwap" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#EngineSwap</a> <a href="https://weird.autos/tags/WrenchEveryDay" class="mention hashtag" rel="nofollow noopener noreferrer" target="_blank">#WrenchEveryDay</a>

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