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    • DCT Build Part XII - Build complete, pictures of final assembly, transmission cooler, and Viton seals

      Well, this has been a rather lengthy road to completion but the transmission is basically complete. The car was dropped off by SSP last month to Gintani who should have the motor in by the end of this week. The problem is SSP mounted their trans cooler in the location the heat exchanger for the supercharger needs to go so SSP will need to come to Gintani's facility to re-run their lines as the cooler will need to go in a different location. What took so long for this update? Well, we have been waiting, and waiting, and waiting for SSP to send us details on the Viton seals that required 3 redesigns but never received the information on why these seals are superior to the stock units.

      So, I decided to do my own research and here is what I came up with. These are the stock BMW seals used in the DCT. What is wrong with them exactly? We do not know other than they apparently are not up to the task:










      Here are the Viton seals which delayed the project by 3 months. Viton is a synthetic rubber used for seals, O-rings, things of that sort. Viton was likely used as it is less susceptible to decay and already used in BMW applications such as in VANOS. Viton has much higher temperature and chemical resistance characteristics than the stock seals. Here is what they look like:










      This is the DCT cooler that was mounted by SSP up front. This needs to be moved somewhere else as the supercharger heat exchanger will need to go there. This means SSP will need to come out and run their lines again checking all their fluids and so forth before tuning can take place:














      This is the final assembly. So, the transmission is built but it took about a year longer than estimated. I believe I was as patient as possible and hopefully this will all be wrapped up in December with a built motor, built transmission, a YSI, and a ton of horsepower.






































      This article was originally published in forum thread: M3 DCT Build Journal - World's First BMW DCT Build started by Sticky View original post
      Comments 2372 Comments
      1. Linracing's Avatar
        Linracing -
        This thread went insane. Money, and who's parents had it worse ? -_- My family where slaves and I don't bring that up. I am 28 years old and have three cars my own house, my own business but I am not as happy as I can be. Money does nothing for me.
      1. Sticky's Avatar
        Sticky -
        Oh so now you want to do DCT research Kris?

        Click here to enlarge
      1. Ak335i's Avatar
        Ak335i -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        Oh so now you want to do DCT research Kris?

        http://www.benzboost.com/images/impo...04/3rTtI-1.png
        i wonder can he make my 6at handle what I'm gonna throw at it jajajaja
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by Ak335i Click here to enlarge
        i wonder can he make my 6at handle what I'm gonna throw at it jajajaja
        Give him your trans for a couple years and find out .
      1. leo985i's Avatar
        leo985i -
        Click here to enlarge Originally Posted by keikdasneak Click here to enlarge
        This thread went insane. Money, and who's parents had it worse ? -_- My family where slaves and I don't bring that up. I am 28 years old and have three cars my own house, my own business but I am not as happy as I can be. Money does nothing for me.
        Well said brother.
      1. fastgti69's Avatar
        fastgti69 -
        I just want to see 800whp in a stage 3 DCT SC M3.
      1. c32AMG-DTM's Avatar
        c32AMG-DTM -
        Wow, this thread has gone bananas.

        Honestly, it would be great if someone would do a Cliff's Notes of the relevant DCT info/timeline.

        I'm not going back to look it all up, but from memory, I think it goes something like this:

        1. Sticky buys a DCT e9x M3.
        2. Sticky puts a blower on his M3.
        3. Sticky does a ton of drag-strip passes with his blown M3, and completely trashes his stock OEM DCT. Can't buy just replacement clutches, because it's all too new. It's either buy a whole new DCT from the dealer for crazy $$$, or find someone to rebuild the stocker that got trashed.
        4. Sticky investigates rebuild options. No one has done one yet. No one is particularly interested in doing one, either, but SSP offers to rebuild it on their own dime if they get the R&D out of the deal.
        5. SSP takes a looong time to rebuild Sticky's DCT.
        6. Gintani takes a looong time to build Sticky's motor and install his newer, bigger blower kit.
        7. Once all of the hardware side is completed, Gintani starts dyno tuning Sticky's car. The brand-new SSP clutches hold WOT dyno pulls on pump fuel, and allegedly set a new pump-fuel record for an e9x M3. Then race-fuel tuning starts, and the DCT starts slipping.
        8. Sticky reaches out to SSP to let them know, and SSP decides they no longer want to be involved with this ongoing project anymore.
        9. A nasty back-and-forth series of posts breaks out here on GB between SSP and Sticky.

        ^^^Does that basically sum it up, or am I missing any critical steps so far?
      1. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by c32AMG-DTM Click here to enlarge
        Wow, this thread has gone bananas.

        Honestly, it would be great if someone would do a Cliff's Notes of the relevant DCT info/timeline.

        I'm not going back to look it all up, but from memory, I think it goes something like this:

        1. Sticky buys a DCT e9x M3.
        2. Sticky puts a blower on his M3.
        3. Sticky does a ton of drag-strip passes with his blown M3, and completely trashes his stock OEM DCT. Can't buy just replacement clutches, because it's all too new. It's either buy a whole new DCT from the dealer for crazy $$$, or find someone to rebuild the stocker that got trashed.
        4. Sticky investigates rebuild options. No one has done one yet. No one is particularly interested in doing one, either, but SSP offers to rebuild it on their own dime if they get the R&D out of the deal.
        5. SSP takes a looong time to rebuild Sticky's DCT.
        6. Gintani takes a looong time to build Sticky's motor and install his newer, bigger blower kit.
        7. Once all of the hardware side is completed, Gintani starts dyno tuning Sticky's car. The brand-new SSP clutches hold WOT dyno pulls on pump fuel, and allegedly set a new pump-fuel record for an e9x M3. Then race-fuel tuning starts, and the DCT starts slipping.
        8. Sticky reaches out to SSP to let them know, and SSP decides they no longer want to be involved with this ongoing project anymore.
        9. A nasty back-and-forth series of posts breaks out here on GB between SSP and Sticky.

        ^^^Does that basically sum it up, or am I missing any critical steps so far?
        nope, looks good
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by c32AMG-DTM Click here to enlarge
        Wow, this thread has gone bananas.

        Honestly, it would be great if someone would do a Cliff's Notes of the relevant DCT info/timeline.

        I'm not going back to look it all up, but from memory, I think it goes something like this:

        1. Sticky buys a DCT e9x M3.
        2. Sticky puts a blower on his M3.
        3. Sticky does a ton of drag-strip passes with his blown M3, and completely trashes his stock OEM DCT. Can't buy just replacement clutches, because it's all too new. It's either buy a whole new DCT from the dealer for crazy $$$, or find someone to rebuild the stocker that got trashed.
        4. Sticky investigates rebuild options. No one has done one yet. No one is particularly interested in doing one, either, but SSP offers to rebuild it on their own dime if they get the R&D out of the deal.
        5. SSP takes a looong time to rebuild Sticky's DCT.
        6. Gintani takes a looong time to build Sticky's motor and install his newer, bigger blower kit.
        7. Once all of the hardware side is completed, Gintani starts dyno tuning Sticky's car. The brand-new SSP clutches hold WOT dyno pulls on pump fuel, and allegedly set a new pump-fuel record for an e9x M3. Then race-fuel tuning starts, and the DCT starts slipping.
        8. Sticky reaches out to SSP to let them know, and SSP decides they no longer want to be involved with this ongoing project anymore.
        9. A nasty back-and-forth series of posts breaks out here on GB between SSP and Sticky.

        ^^^Does that basically sum it up, or am I missing any critical steps so far?
        That's basically it although I did a ton of drag passes before the blower. People forget I had the NA record too.

        Although I would also say SSP never got the project right in the first place despite taking their sweet time.

        It's not the issue with the clutches holding however. It's the trans shifting gears randomly, going into neutral, just not doing what it should. We found out why.
      1. c32AMG-DTM's Avatar
        c32AMG-DTM -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        It's not the issue with the clutches holding however, it's the trans shifting gears randomly, going into neutral, just not doing what it should. We found out why.
        That sounds like a software/coding issue...? TCU not talking to the hardware properly and vice versa?
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by c32AMG-DTM Click here to enlarge
        That sounds like a software/coding issue...? TCU not talking to the hardware properly and vice versa?
        No, not software.
      1. c32AMG-DTM's Avatar
        c32AMG-DTM -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        No, not software.
        Okay - fair enough. I'll wait to hear what the issue was, when you're ready to post it. My thinking was, if the clutches were one of the primary changes, and quirky behavior like random shifts, going into neutral when it shouldn't, etc. is happening - something in the electronic chain might be acting up. Unless SSP got the basic dimensions/spacing wrong within the box...?

        Anyway, again - sorry to hear you're going through this... pioneering something usually has bumps along the way, but this has seemingly had more than its fair share.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by c32AMG-DTM Click here to enlarge
        Okay - fair enough. I'll wait to hear what the issue was, when you're ready to post it. My thinking was, if the clutches were one of the primary changes, and quirky behavior like random shifts, going into neutral when it shouldn't, etc. is happening - something in the electronic chain might be acting up. Unless SSP got the basic dimensions/spacing wrong within the box...?
        I mean you're right in a sense that the elctronics are telling the trans to go into neutral or shift. But it's because of a hardware issue as the dct computer isn't getting what it's expecting from the hardware. They upped the line pressure to the max and it simply wasn't that. It's actually something pretty basic that caused all of this and they are seeing if they can fix it. Funny how the "dct experts" messed this up and a tuner who doesn't even specialize in this transmissions managed to notice it. I'll have more soon.

        Click here to enlarge Originally Posted by c32AMG-DTM Click here to enlarge
        Anyway, again - sorry to hear you're going through this... pioneering something usually has bumps along the way, but this has seemingly had more than its fair share.
        It's really not that big of a deal. Others make a far bigger deal about the bumps and the time than I do. Others also use the bumps and time to put me down but those aren't the enthusiasts.

        Then there are some like SSP who want to shift the blame away as quickly as possible making up whatever is necessary to do so. Everything will be set straight in due time, hopefully this next week. Nobody is going to ever want to use SSP for anything ever again.
      1. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        It's the trans shifting gears randomly, going into neutral, just not doing what it should. We found out why.
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        I'll have more soon.
        explain
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by LostMarine Click here to enlarge
        explain
        I'm supposed to explain what 'I'll have more soon' means?
      1. Ak335i's Avatar
        Ak335i -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        I'm supposed to explain what 'I'll have more soon' means?
        dont try to use logic here, the mentality is that you are supposed to drop everything and tell every detail about your car everytime some one asks Click here to enlarge
      1. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by Ak335i Click here to enlarge
        dont try to use logic here, the mentality is that you are supposed to drop everything and tell every detail about your car everytime some one asks Click here to enlarge
        or
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        We found out why.
        makes it sound like there is information to be shared.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by LostMarine Click here to enlarge
        makes it sound like there is information to be shared.
        Yes, there is. I'll share as soon as I find out what they figure out.
      1. DFM's Avatar
        DFM -
        The sense that I get is that sticky has a vague understanding of what the problem might be, but he wants to be 100% certain before posting about it. And there is absolutely nothing wrong with that. I could be wrong...
      1. Autobahn335i's Avatar
        Autobahn335i -
        Click here to enlarge Originally Posted by DFM Click here to enlarge
        The sense that I get is that sticky has a vague understanding of what the problem might be, but he wants to be 100% certain before posting about it. And there is absolutely nothing wrong with that. I could be wrong...
        Nah, Sticky is a attention whore and just wants to build up suspense LOL

        I'm interested in the findings too. DCT is really the only way to go in an M3!

        I wonder what german tuners like Manhart Racing or Hamann would say on these issues. I know they can handle whole engine and transmission swaps, so maybe they also have something up their sleeve to strengthen the DCT? Maybe Sticky should reach out in that direction?