E30 - 325iS: Automatic to Manual swap
*NOTE: To make this swap easy on yourself, FIND A COMPLETE DONOR CAR!

Disassembly of my car:

Step 1: Remove front exhaust section. Remove bolts attaching to rear exhaust section (4 bolts and nuts). Remove the 6 14mm nuts attaching to exahust manifolds (These should be sprayed with penetrating lube to prevent breaking, I use PB Blaster). I used a 14mm socket, a universal on that and a VERY long extension (approx 24in), and a long handle ratchet. If they have never been off, they are very tight, just give em hell, they will break free. Then, loosten the mount on the trans. Pry back the rear exhaust section to free it from the front and the front section almost falls out (Watch the O2 sensor!).

Step 2: Remove heat/splash shield. there are 10 bolts attaching this to the underbody, 8 of them are 14mm, 2 of them are 10mm. they come out with no problem. there is what looks like a trans crossmember at the front of the sheild that holds it in place, take it out, nothing heavey will fall on you. the 2 10mm screws are at the back of the sheildnear the differential, also come out easy.

Step 3: Remove Driveshaft. Spray your lube of choice on the attaching bolts on the front and rear of the driveshaft. the front is where the guibo is at, i removed the guibo from the trans and left it on the driveshaft. Remove the center support bearing, 2 14mm bolts holing it in, let it hang. Remove the tranny crossmember and let it all hang down (its not going anywhere), that is held in with 3 14mm nuts. then remove the crossmember from the trans, i believe there are 2 13mm or 14mm (dont recall, my mount was broken so i didnt have to) nuts holding this on to the trans. the guibo is held to the trans with 3 17mm nuts and bolts, also on rather tight. I used a 17mm combo wrench on the nut side and used a 17mm socket, short extension and a 3/8" drive impact wrench to get these off, did it in a snap (not literally). remove the rear of the driveshaft. this has 4 17mm nuts holding it in place. with a carefully positioned prybar and a 17mm combo wrench using the box end, i got those off. then with a bit of maneuvering, pull out the driveshaft and do what you want with it, its services are no longer needed.

Step 4: Remove the trans. Disconnect the shift linkage by pulling off the clip and sliding out the pin. remove the cooler lines going to the radiator, if memory serves me, i think they were 18mm. the lower hose is easy, the upper one is a bit tough. Or if you dont feel like messing with it all, cut them so they are not in your way, they will no longer be needed, doesnt really matter. remive the 4 13mm bolts attaching the inspection pan to the block and the 4 E___ bolts holding the inspection pan to the trans then pull it out. There are     bolts attaching the trans to the block, they are E___ bolts (inverted Torx). Then there are 2 E___ bolts with 17mm nuts than attach the starter to the trans. if you start by spinning the solts loose with the impact, you can get the nuts off by hand, otherwise, you get to figure out how to get a wrench in there to hold them (you have my blessings if you do). there is a 10mm bolt holding a piece of sheet metal to the trans, take it out. It is best that you take out the torque converter with the trans, there are 3 17mm bolts holding this to the flexplate, a long ratchet and a socket are best, use a long screwdriver to rotate the flexplate to get at them. after all this, cut the cable running to the trans, its either a kickdown cable or for the cruise, not sure. then get a jack under it and finegle the beast out, it may taking a lil prying and wiggling, but it comes out. and to lighten the load, get out as much fluid out as possible, it is HEAVY, especially the front. Then do what you wish with this, also no longer needed.

Step 5: Removing gear selector. remove rear sectionof the center console, 1 10mm plastic nut under rear ashtray, pull up a bit, back a bit, and slide it off of the e-brake handle. next, pull off the plastic cover to the right of the gear selector with the brush thingy attached to it, just pulls off. remove the 2 phillips screws to remove the gear indicator bezel. then, remove the 1 10mm plastic nut to the rear of the selector assembly. there is 1 8mm screw going straight up that is under/behind the heater control, get at it from in front of the front ashtray, i used a ratcheting box wrench. then pull up on the back of the console and wiggle it out. once this is out, there are 2 more 10mm bolts holding down the selector at the front of it, pull them out, then disconnect the plugs and pull it out.

Step 6: Removing pedel assembly.
More to come as the project progresses!
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