Most liked posts in thread: The Phoenix - The GP Roadster Project

eBay is your friend. Do an advanced search for user "diy_bmw_garage"

Or just search for DIS GT1 INPA NCSexpert
I can't attest to the legitimacy or support of any of the sellers except the one I named above.

And, of course, this is all hypothetical. I would never encourage the use of any BMW software not obtained directly from BMW for zillions of dollars.

 

Sooooo.... replaced the faulty solenoid in my rebuilt transmission valve body yesterday. That resolved one specific issue with the transmission, but a test drive confirmed that I've got bigger problems.

Looks like I've done some combination of spinning the K-2 clutch seal sleeve (common problem), and burning through some clutches (probably the torque converter lockup clutch, and perhaps others).

So transmission rebuild is in my near future.

Here's the transmission service manual. I have a hardcopy on the way.
TF60-SN, 09G, 09M.pdf

Here's a good exploded view:
http://www.makcotransmissionparts.com/mm5/graphics/Catalog-pdf/AWTF60SN.pdf

Here's the Sonnax replacement K-2 clutch sleeve for the one that spins - available from multiple sources:
K-2 Clutch Seal Ring Sleeve Kit - 15759-01K - Sonnax

Here's a supplier for the parts (there are others):
VW 09M, 09G, Aisin TF60SN Transmission Parts Volkswagon / Audi

I'm probably going to replace the torque converter and rebuild ALL the clutches while I have the thing apart, plus all the seals and such that you have to replace when you do the rebuild. After all that, I should, for practical purposes, have a better-than-new transmission.

Bummer that you have to pull the engine to get the transmission out. That should be fun.

At least I can install the new heater hose assembly I bought a couple of years ago and didn't install.

Anyone have any suggestions for other things to do while I have the engine out? All suggestions are welcome, including "swap to a manual transmission"... I'll just ignore those.

 

Did the rebuild this weekend. Decided to writeup the process and all the supporting info in a separate thread, for the library.

Here.

 

GP Roadster?

So back when I started this, I said that my vision was to build a "GP Roadster" - something like a drop-top version of a 2006 MINI GP.

Well, if that's the vision... and if I need a donor car to convert to manual... then I might as well go big, or go home.

My donor car, just won at auction this morning:



Very sad, actually. I do this with huge mixed emotions. :sad:

I feel a bit ghoulish. But, if the car is totaled, might as well preserve as much as we can in a different form. I'll try to do it respectfully.

 

FrankenGP: Weekend One

Long weekend, I probably put in close to 20 hours on the car. Made much progress.

I'll do a more detailed writeup on my blog in the next day or two - but here are some highlights:

Most things on the front of the engine were pretty crushed, as expected. Casualties included:

• Radiator
• AC Condensor
• Alternator
• Intake Manifold
• SC Intake duct
• Snorkel
• JCW Airbox (sadly - cracked)
• Transmission mount
• Lower engine mount
• Bumper cover
• Alloy Bumper
• Fan assembly
• Valve Cover
• Coil
• Intercooler cover

That's a lot, but only a few things in there I didn't expect, and none that are critical to my project.

Broken valve cover was a bit of a bummer


But I was able to salvage the important part.



Surprised to see the intake manifold shattered, but no big deal. My other one is ported, anyway.


Took most of a day to do "exploratory surgery" and get the broken stuff off.

Charged the batteries (yes, it has two little ones) overnight, and this morning, LIFE!

Enabled me to get the hatch open. Then I removed the catch so it wouldn't latch again.

Pulled exhaust (a nice Milltek, already sold), brake calipers, underbody panels, GP side skirts, lots of trim, heat shields...



I'll be re-using much of this stuff.

Axles have seen better days, but I think I can recondition them.


Finished removing engine. Easier after doing Blimey's previously.


Started pulling out the dash, removed the shifter and cables.


Only things I have left to do on this car before I can do the transplant, are remove pedals, clutch lines, key cylinder and other needed computer modules. Lots of prep work to do on the engine next weekend before it's ready to implant in the roadster. Needs a lot of cleanup, and installation of several things over from Blimey's current engine to replace broken and inferior parts.

This looks like someone has a serious condition. But foreshadows things yet to come.


First sacred piece of GP0769 transplanted on a new chassis. There will be many more.

 

That's the plan. All that will happen 3/27-3/28 if we stay on schedule.

 

So I think everything is off the GP that I need right now.

Got the garage cleaned up and shoved the GP carcass into the back corner, to make room for the cabrio. Got all my parts organized. Everything that I need is either on the engine, or in a big box. Everything that can wait til later got shoved in or on the carcass before I rolled it out of the way.



All the donor parts, and some new parts. The rest of the new parts are coming in the next several days.



I thought I was going to rebuild these axles, but just discovered that one of the tripod bearing assemblies is toast. Ordered a pair of remanufactured axles instead, will return the boot kits I bought for this set.

 

After a morning in the office, spending the afternoon in the engine shop.


After some thought and inspection, decided to stick with the Blimey engine for now. I just reconditioned it recently, it's running very strong, and I know how well it has been maintained. After looking at the heads, I think my current head is at least as good as the GP's, probably better. And far less rust and corrosion. I'll save the GP engine for a later build core.

So, swapping over all the manual stuff - mostly coolant and oil systems and brackets. Plus the tranny.

Sensing its doom, the torque converter expels all its bodily fluids, in a final act of defiance.


In the immortal words of the Geto Boys...
Die MoFo Die MoFo Die!!!