LIST OF UPDATE: Clutch Master and Slave Cylinder, Front Strut Brace, Rear Brake Pads

Replacing Clutch Master & Slave Cylinder for E30

ok... before i start.... i would rather not doing this again as it is too hard on my back... the location of the master cylinder under the steering wheels is hard to reach! took me 3 hours to do it... qualified mechanic probably can do it in 1 hour or less...

the slave cylinder in contrary is very easy... just unbolt 2 13mm holder bolt and unbolt the fluid line. then install the new one... pretty straight forward, i did it in 10min...

here are the Master Cylinder replacement...

first thing is to unbolt the bleeding nipple on the slave and pump the clutch pedal to empty all the fluid.... then i unbolt the output pressure line from the engine bay...


and then i had to unbolt the 2 bolt holding the master cylinder


because the accelerator cable was on the way i keep the throttle open so it pull the cable out of the way...


and i remove the bottom reservoir hose... then i can pull the master and the flex hose out... and then remove the inlet coupling... at last its out... will need to remove the rubber seal around the old one to the new one


replace the inlet coupling into the new master cylinder and bolt everything up in reverse order...



Rear brake replacement
i also replace the low rear brake pad with the original BMW pad i had as a spare...


Whiteline Front strut Brace
bring this one back from melbourne... nice fit... tighten up the handling feel around the corner entry...

GEARBOX PART 3: ASSEMBLY

GEARBOX PART 3: ASSEMBLY
Removing front casing of the 1985 GETRAG 240 to be swapped with my 1983 GETRAG 240


confirming with visual comparison first :P

looks identical except for the input bearing hole diameter...

'bottle cap' seal back into place


input shaft bearing fits nicely on the post 1984 GETRAG front casing


rear and front casing bolted in together...


installing bearing locking clip


installing release bearing and the clutch lever


however after all this, when i test the gearbox, it will not shift into 1 - 2 or reverse.... so it had to be opened again and turns out that the gate piston for the 1 - 2 - R are facing the wrong way... the angled side supposed to face the gear shaft... it was facing the other way


all assembled and the car now next i need to install new master and slave cylinder installed...

GEARBOX PART 2: Finding the right bearing or Finding the right casing????

GEARBOX PART 2: Finding the right bearing or Finding the right casing????

my gearbox is Getrag 240 from E28 520i year 1983... and they changed the bearing and front casing input bearing hole from 62mm to 63mm after 1984...

turns out getrag 240 input bearing available on stock by most supplier are 1984 onward with measurements: 63x30x24.8mm and part number: 23121224375 (bottom one on the picture)
 
what i need is the first gen, measurements: 62X30X23.8mm. parts number: 23121224069; from 520i E28 1981-early '84 (top on on the picture)

eventhough the inner diameter is the same between both bearing, it will not fit on my older casing


the rare bearing that i need are interchangeable with:
- E28 518 Sedan, M10, Europe, RHD, MANUAL (1981-84) : GETRAG 240 GEAR WHEEL SET,SINGLE PARTS
- E28 520i Sedan, M20, Europe, RHD, MANUAL (4072) : GETRAG 240 GEAR WHEEL SET,SINGLE PARTS
- E21 320i Sedan 1982, M10, MANUAL (1982) : GETRAG 240 GEAR WHEEL SET,SINGLE PARTS
- E30 318i Coupe, M10, MANUAL (1982-84) : GETRAG 240 GEAR WHEEL SET,SINGLE PARTS

so i also tried requesting for those particular alternatives....

HOWEVER... i still couldn't find it anywhere and ordering from BMW dealer will take 1 months at least....

so i look around and found a GETRAG 240 year 1985! from mr Irs (ianparts.com)... it has broken synchromesh but it mean i can salvage the front casing which has the current bearing available from most supplier! (63x30x24.8mm and part number: 23121224375) which also mean no need to wait for the rare bearing of the pre 1984 anymore (62X30X23.8mm. parts number: 23121224069)

2 box in my boot end my day... will continue on tomorrow...

CLUTCH AND GEARBOX PART 1

CLUTCH REPLACEMENT my poor old SACH clutch in pieces...   the replacement: installed waiting for the gearbox... while the Gearbox is off the car, i decided to fix all the seals (minor leaks from few sections) and replacing the input bearings.... so here we go GEARBOX PART 1: REMOVAL, DISASSEMBLY AND INSPECTION Draining bolt is welded / glued!!! o_O   so i sent the rear housing for machining... to make a new drainning hole and fit bigger bolt   inspection of the front housing, and removal of the main input bearing inspection of the rear housing & gearset... all the synchromesh still in good condition... 1st gear starting to wear... expected... damaged input shaft bearing... input shaft is made of ballbearing and roller bearing.... the roller bearing fell apart as soon as we pull the gearbox apart... rear output nut replaced: sign of abuse and improper tool from previous owner... reason being probably because they dont have 30mm socket deep enough to reach the bolt... so they used a chisel to open... the seal on the output shaft also broken... replaced with new one: i bought myself 30mm long socket for $10USD to tighten the output nut... replace the bolt with the spare one i got, also damaged but abit better condition... 'Bottle Cap' seal is being reused as it is still in good condition.. new reverse light switch: new release bearing again abused by improper tool replaced the hex bolt with the spare i got... replacing the Neck input seal:

CAD & RMC Trackday @ Sentul, 10th July 2010

CAD & RMC Trackday @ Sentul, 10th July 2010


First time @ sentul.... VERY FUN TRACK! and the E30 handle very well despite **** Turanza ER10 tyres and leaking strut...

the car only lasted for 2 session though hahaha my clutch gave up...

PB (Personal Best) 2min 08sec (race chrono + Nokia 6110 navigator + Qstarz 1Hz bluetooth GPS)
Speed VS Time graph:


i only had 8 laps. 3 lap in the morning for familiarization, 4 laps timed with GPS timer (session 1 and 2). tyre pressure 36psi (cold), bridgestone turanza ER10
Warm up lap session1- 2m34s
Lap 1 session 1: 2m12.7s
Lap 2 session 1: 2m11.6s
Lap 3 session 1: 2m10.4s
tyre pressure jump to 41psi after 3 lap... i put it down to 32psi hot

Warm up lap session 2- 2m22s
Lap 1 session 2: 2m8.7s **PB (Personal Best)**
Lap 2 session 2: DNF *Clutch drop to the floor on big S turn...
return to pit...

Hope will fix the problem soon

after 2nd session, my clutch pedal goes flat to the floor and stayed there o_O and i had no clutch at all... Had to clutchless shift for half of the lap... Back to the pit... Thx to ronny and melly for helping me handing out the tools while im under the car...

Looks like the seal on the clutch hydrolic slave has burst.. Fluid everywhere...

"Here we go.... Today is public holiday so no way i can get the replacement asap.... Had to end the day with 2min8sec personal bestlap... Next time sentul!!!! 
thx to my melly for taking photo while my hand covered with fluids and dirt.... and thx for the patience 
"