6AT to DCT Converstion

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doublespaces

Administrator
Oct 18, 2016
7,447
AZ
Credits to ncat10(Oleg) for this tutorial!

Thanks to @BMWJunkie for the correct ZUB# and this tip:

"I would also highly advise to test the vehicle with the stock clutch and perform all four transmission calibrations successfully on the stock clutch before installing aftermarket clutches. Doing otherwise could damage clutches if the transmission, wiring, or programming is not functioning 100%."


A full diagram is provided as the download attachment which most people have not seen.

Part1 ( Hardware parts )

-12 51 7 581 112 – wiring
-83 22 2 147 477 - DCT Oil 8l.
-51 16 9 141 518 - Cover center console
-61 31 9 133 067 and 61 31 9 213 647 - gear selector
-61 31 9 192 483 - park system for DCT
-DCT Transmission (GS7D36SG from E9X/E89 n54 n55 )
-DCT flywheel. Very important.
-If you have 2009.01+ car you number is - 21 20 7 590 853 ( 6 bolts 11 22 7 520 706 )
-If you have 2009.01 < car you number is - 21 20 7 593 469 ( 8 bolts 11 22 7 520 706 )
The different about flywheel only in bolts pattern.
-Rear differential 2.56

Part2 ( ECU parts ) ( If you have 2008/09> just skip this part )

MSD81 ECU (12 14 7 616 431 ) - if you have 2008/03 just skip this part
DSC Pump (34 51 6 789 308 or 34 51 6 863 356 ) - if you have 2008/09 just skip this part
DSC Sensor (34 52 6 780 334 or 34 52 6 850 375 ) - if you have 2008/09 just skip this part
DSC Sensor plug (http://www.realoem.com/bmw/showparts...95&hg=34&fg=20 ) - if you have 2008/09 just skip this part
I can’t find this part #17 . But I buy used harness from car 2009+ and get this plug from it.
JBE2 or JBE3 ECU (61359286790 ) - if you have 2007/09 just skip this part
DCT shift paddles or m3 shift paddles

Part3 (harness to DCT Gear Selector )
You should to made the wiring harness for DCT gear selector switch.
Use this link to download scheme. ftp://share:[email protected]/DCT/
You should to made and integrate the harness, marked blue color in my scheme
To do this you need following parts:
4 pin jack plug 61 13 8 380 696
2 pin jack plug 61 13 6 925 634
and also 6 pins 61 13 0 005 197 - 6
61139132577 - 10 pin GWS socket housing

Harness:
DCT.jpg

Part4 ( Replacing JBE ECU ) ( if you have 2007/09 > skip this part )
You can find JBE ECU under the feet of the passenger seat.
First you should replace it on new one JBE2 or JBE3 ECU (61359286790 ).
After this you should integrate D-can bus line for new ECU. ( Old cars have K-line and new ECU will not work )
Change pin on OBD2 socket
7 to 14
and put the additional wire between OBD2 socket pin 6 and JBE ( blue connector ) pin 17
IMG_0012.jpg

Part5 ( Replacing DSC ECU ) ( if you have 2008/09 > skip this part )
Replace DSC unit on new one.
Replace DSC sensor on new one. ( You can find DSC sensor under drive seat, under carpet )
1097443.png

Replace DSC Sensor Plug. The DSC sensor should be connect to DSC unit follows
DSC UNIT > DSC Sensor
39 > 4
27 > 2
11 > 3
28 > 1
After this you should calibrate your DSC unit and sensors. ( use bmw ISTA to do this ),

Part4 ( Replacing MSD80 on MSD 81 ) ( if you have 2008/03 > just program it )
Replace you MSD80 on 81.
Very important! you can't use used MSD81 unit. you should buy it new
Program it on Zub 7628542
Do not forget to transfer values about injectors in the new MSD81.

Part6 Programming and Coding
I use NCS Expert and Win KFP to program and code my car
Remove FA $205
Remove value that starts # and Add #0909
Add FA $2TC
Make FA write on CAS and NFRM
Code ECU: MSD81/CAS/Kombi/IHK/JBFE/NFRM/GWS
Program MSD81 on Zub 7628542
Program GS40 on Zub 7600042
Update you Kombi/NFRM/GWS

---
You have to stay within 10% of the 2.56 gear or you will set transmission faults
135i Shift knob is not compatible with 335i, the shift boot baseplate is different.

https://www.newtis.info/tisv2/a/en/...ansmission-control-unit/transmission/q-A70020
 

Attachments

doublespaces

Administrator
Oct 18, 2016
7,447
AZ
I've been considering this more lately. I keep wanting to just buy a 335is, but I don't really feel like starting over with a new car considering a lot of the custom stuff I've done.

Regarding the M4 Flywheel, what happened to the @MFactory SMFW option? And what about those who machined off the dual mass portion, I've read that it does and doesn't work depending on who you ask.

Is there a guide to building this harness as well, perhaps some information on where to source that 10 pin connector which is used? Perhaps we could get one 3D printed.
 

doublespaces

Administrator
Oct 18, 2016
7,447
AZ
Look at this chart and you'll see the same drive shaft with part number 26107614433 is used for the automatics as well up to September 2007 build dates:
iLT6uWV.png


The only real difference is the length of the shafts, and this is because there is a large and small pumpkin for our cars. Manual, DCT and diesel autos are all large housings. The automatic was large as well until late 2007 and then went to the small housing from then on. The main difference is the length of the differential housing(fore of the differential cover) which causes a difference in the drive shaft length. But this is completely negligible as far as I can tell because the drive shaft is telescopic so you can simply extend or retract the shaft slightly to compensate. @BMWJunkie was kind enough to supply side by side photos showing the difference in the shafts, axles and differential housings here:
https://bmw.spoolstreet.com/threads/swap-188mm-auto-pumpkin-for-215mm-diff-cover-options.1561/

Basically it amounts to no changes being necessary. The auto axles will fit either housing(I'm currently running small housing axles in a large housing) and the only thing which requires custom attention is mounting the differential cover. Some covers are thicker than others so in some cases you'll need to make a spacer and use a larger bolt to secure the differential cover to the subframe.
 

Brett Shepard

Lurker
Nov 5, 2016
17
Jacksonville
The difference between DCT and later auto is just under an inch. I wouldn't trust compressing an auto driveshaft that much. The combined movement between subframe, engine and diff could exceed the tolerance. I would just have it cut down an inch. I haven't priced it but probably cheaper or comparable to buying a used driveshaft. Obviously those of us not on stock bushings and mounts will have far less movement.
 

doublespaces

Administrator
Oct 18, 2016
7,447
AZ
The difference between DCT and later auto is just under an inch. I wouldn't trust compressing an auto driveshaft that much. The combined movement between subframe, engine and diff could exceed the tolerance. I would just have it cut down an inch. I haven't priced it but probably cheaper or comparable to buying a used driveshaft. Obviously those of us not on stock bushings and mounts will have far less movement.
Myself and others have been running the AT shaft with a large diff and have not heard of any issues. I do have AKG black diff mounts and 034 driver/urethane pass motor mounts however. Also, isn't the M4 shaft a one piece design? I don't think it has a slip joint at all, or does it?
 

aus335iguy

Lieutenant
Nov 18, 2017
950
Question - has the e92 M3 DCT driveshaft been compared to others as has been done here? If i was to go an M3 diff could a similar shaft be used instead of custom?
 

doublespaces

Administrator
Oct 18, 2016
7,447
AZ
Question - has the e92 M3 DCT driveshaft been compared to others as has been done here? If i was to go an M3 diff could a similar shaft be used instead of custom?
I would think a shaft that was close should work if it has a slip joint, but I don't know if any exists. It has worked in my case anyhow. I'd be surprised if the flywheel of an I6 and V8 were in the exact same spot, but I have no idea.
 

doublespaces

Administrator
Oct 18, 2016
7,447
AZ
For anyone who is curious, this is the 10 pin connector on the GWS (shift selector) that does not have a male counterpart available for purchase:
20180203_221000.jpg

And here is the male connector, X511:
X511.png

And this connector will look similar to the shift knob connector, but with 10 pins instead of 12:
20180203_223121.jpg
 

doublespaces

Administrator
Oct 18, 2016
7,447
AZ
After wasting a night with a multimeter mapping out pin continuity and looking up pictures of harnesses, I started to suspect the wrecking yard sent me the wrong harness. The 135i harness doesn't have the same connector bracket inside the ecubox, its skinnier, and the pins did not match up the way the DCT harness diagram showed. I went outside and poped the ECU box open on my car and noticed my auto stuff looked just like this. I pulled up an auto harness on the TIS and confirmed my pinouts matched an automatic transmission harness. So I'll need to acquire a brand new DCT harness unless I can find a used one.

Also, I got a reply back from Tyco on the 10 pin connector. I inquired about the 12 pin connector simultaneously so I'm not sure which one they are replying about, regardless the outcome is likely the same:

Hello Tyler,

Happy Sunday!! Hope you had a fun and relaxing weekend.

In regards to your inquiry for TE Internal #1456636-1, the part is Restricted for Sales.

If you want to buy the part you need to get an LOA (Letter of Authorization) either from Dom Samochodowy Germaz or Friedrichshafen Ag company as they own this part.

Thanks for your inquiry.

If you have any further inquiry, please contact us anytime. We are happy to help you.

Looking forward to your response.

Thanks & Regards,
Daya S
TE Connectivity
Technical Support Center
http://www.te.com
For Support: http://www.te.com/help
800-522-6752 x2
I've asked them for contact information just for kicks, and I've got a part inqury out with a guy at a dealership who has been unusually good at tracking this type of stuff down.
 
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