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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. meinauto's Avatar
        meinauto -
        Click here to enlarge Originally Posted by jjv104 Click here to enlarge
        The SC supplier wouldn't tell me. My understanding is he works for many OEMs doing software. The only other clue is the guy is/was a champion kick boxer.
        Hmm... champion kick boxer? If we are talking about the same guy, he is indeed the guru and has a very unique m3
      1. meinauto's Avatar
        meinauto -
        and yes, the issue with the M3 DCT with high power applications is the pressure, not the clutches
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by BMWJunkie Click here to enlarge
        Whatever you decide to do please make sure you give whatever clutches you end up with in your car a good 1000 miles of city driving before doing anything. I know the clutches in my DCT were never the same after going to the track at 1200 miles. Not to mention the GTR tech I talked to said he recommends minimum 1500 miles to 3000 miles of no sport shift and nothing over 5k to let the clutches wear in properly. You can bet your ass when my 2nd 335is shows up in a month that it will be driven very very moderately for 2000 miles.
        Kind of funny considering a couple "experts" were saying how break in should be done after a few hundred miles without ever even taking into account breaking in the DCT.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by meinauto Click here to enlarge
        and yes, the issue with the M3 DCT with high power applications is the pressure, not the clutches
        In this case it's the clutches not the pressure.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by meinauto Click here to enlarge
        Hmm... champion kick boxer? If we are talking about the same guy, he is indeed the guru and has a very unique m3
        Who is he and if he is a guru why didn't he get it to work?
      1. ZooyorQ's Avatar
        ZooyorQ -
        Click here to enlarge Originally Posted by BMWJunkie Click here to enlarge
        Whatever you decide to do please make sure you give whatever clutches you end up with in your car a good 1000 miles of city driving before doing anything. I know the clutches in my DCT were never the same after going to the track at 1200 miles. Not to mention the GTR tech I talked to said he recommends minimum 1500 miles to 3000 miles of no sport shift and nothing over 5k to let the clutches wear in properly. You can bet your ass when my 2nd 335is shows up in a month that it will be driven very very moderately for 2000 miles.

        Secondly John Shepard is probably the most stand up guy I have ever met in the car business. His shop is next to his house, its his life. I mean come one, who lets the customer use the bathroom in their own home LOL. He builds an amazing transmission and put together a pretty insane stroker motor for my DSM in 2004.
        That seems excessive. My triple disk in my e46 wouldn't last 5k miles of pure city driving. I think 100mi of city driving should be enough to break in just about any clutch.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by ZooyorQ Click here to enlarge
        That seems excessive. My triple disk in my e46 wouldn't last 5k miles of pure city driving. I think 100mi of city driving should be enough to break in just about any clutch.
        You have two sets one for each other gear though in theory so it should mathematically take twice as long.
      1. ZooyorQ's Avatar
        ZooyorQ -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        You have two sets one for each other gear though in theory so it should mathematically take twice as long.
        I can see that and I imagine with dct there is significantly less 'slipping' so there for less wear on material. But 2000mi seems insane.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by ZooyorQ Click here to enlarge
        I can see that and I imagine with dct there is significantly less 'slipping' so there for less wear on material. But 2000mi seems insane.
        I think 2000 miles is too much too but the point being it definitely is important to break these in properly.
      1. BMWJunkie's Avatar
        BMWJunkie -
        2000 miles is probably excessive but since nobody can tell for sure I'm going to be safe then sorry. Since the launch control is disabled until 1200 miles (not just on m3's) that bmw wants it to be treated somewhat moderately until then. I feel that in my vehicle (335is) I'm going to leave it in drive without sport on so the shifts are soft and at low rpm for 2000 miles. It will be tough but its not like I didn't just beat the hell out of one for 38k miles.

        I put a tune on my car at about 500 miles and took it to the drag strip at 1200. After the 10 or so runs my sport shifts were never as snappy. I'm a firm believer I beat on it too soon.

        Fwiw I'm a 7 year BMW master tech and enthusiast.
      1. e38 prototype's Avatar
        e38 prototype -
        Did you try resetting the TCU yet? Click here to enlarge
      1. jjv104's Avatar
        jjv104 -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        Who is he and if he is a guru why didn't he get it to work?
        He couldn't figure out why the SC tune was affecting the DCT either. The SC supplier wanted to keep testing, but I pulled the plug on the upgrade and took it out.
      1. jjv104's Avatar
        jjv104 -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        Well a brand new trans is off the table as it isn't necessary at this point as even just buying a used trans and switching the clutch pack makes more sense. But, $10k is at least better than $20k. It's all still retarded expensive when BMW should just offer the parts.
        Why don't you just install OEM clutch packs? I believe BMW sells them separately. They show up as a separate part on realoem.com.
      1. jjv104's Avatar
        jjv104 -
        [QUOTE=Sticky;441425]Any way you can find out the name?

        The company is Tribco Inc. in Cleveland. (tribco.com)

        When I spoke to them last year they said they could reline the BMW clutch plates and make new plates if necessary. Prices were considerably less than SSP. They also have a lot of info on clutch material on their site.
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by jjv104 Click here to enlarge
        Why don't you just install OEM clutch packs? I believe BMW sells them separately. They show up as a separate part on realoem.com.
        Oh I didn't realize they had them separately that's what I was actually planning to do.
      1. Sticky's Avatar
        Sticky -
        [QUOTE=jjv104;442554]
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        Any way you can find out the name?

        The company is Tribco Inc. in Cleveland. (tribco.com)

        When I spoke to them last year they said they could reline the BMW clutch plates and make new plates if necessary. Prices were considerably less than SSP. They also have a lot of info on clutch material on their site.
        This is great info thank you, I'll talk to them. Maybe I can get this SSP junk to actually work?
      1. LostMarine's Avatar
        LostMarine -
        Click here to enlarge Originally Posted by jjv104 Click here to enlarge
        Why don't you just install OEM clutch packs? I believe BMW sells them separately. They show up as a separate part on realoem.com.
        partnumber? i cant find them
      1. Sticky's Avatar
        Sticky -
        Ya please link me.

        Regardless, this will be solved most likely with a stock trans. I don't know what I will do with the one SSP $#@!ed up.
      1. bobS's Avatar
        bobS -
        Click here to enlarge Originally Posted by Sticky Click here to enlarge
        Ya please link me.

        Regardless, this will be solved most likely with a stock trans. I don't know what I will do with the one SSP $#@!ed up.
        Good! Get that car on the road while you wait for a solution....just don't launch the car so the clutches hold up for a bit
      1. Sticky's Avatar
        Sticky -
        Click here to enlarge Originally Posted by bobS Click here to enlarge
        Good! Get that car on the road while you wait for a solution....just don't launch the car so the clutches hold up for a bit
        I'm going to launch it.