The guide below is for retrofitting a ZF8HP45 in a BMW E60 LCI with the engine N52k and the automatic gearbox ZF6HP21
The purpose is to be able to revert back to the default 6HP21 setup with minimum effort
March 2007+ BMW E60 LCI (N52k). 530i, 528i, 525i, 523i
BMW E60 LCI (starting 09/2005) equipped with 6 cylinders engines has DSC8+ module with (47 pins and the 38 pins version in some models)
(e.g. BMW E65 has DSC 5.4).
Unlike the E9x/E8x/E7x platforms which use a junction box JBE, in the E60 LCI platform the gateway to the PT-CAN is the Body gateway Module (KGM).
The rear output flange and mounting points are identical between the 6HP21 and 8HP45 (96mm). However, in some variants ( 8HP45 N55 - 105mm), the 96mm output flange from a 6HP21 or a 8HP45 must be fitted to the swapped 8HP, in order to use the same front driveshaft.
The flange collar nut on both 6hp and 8hp is 34mm. Use a deep 34mm 12 point socket. Tightening torque is 60nm.
The rear mount is an easy adaptation (Reusing the E60 6HP21 crossmember), and there are several OE or aftermarket crossmembers that might bolt in.
Below is a picture of 6HP21 cooling ports:
Alternatively, 19mm to 11mm Fluoro orings can be used for adaption
Mechatronic unit Bosch TCU part is either 8HP45HIS Bosch 0260550075 or 8HP45 Bosch 0260550051
Using a TC from any N55 vehicle (8HP) in case of a boosted/charged N52 is recommended
Respecting the torque specifications for mating the transmission to the engine, is critical
For rewiring, creating an adapter is the best solution, by using the OE female connector and a custom male socket.
Once the rewiring and connection to the 8HP is done, the EGS TCU must have its ISN reset
Using an updated Dcan cable along with WinKFP, ISTA-P Expert mode or BTT TQ, with one of the ZUSB firmwares below
If the car is not equipped with Sport E-shifter, the user can still optionally retrofit the M5 (61317834518 / 51168045434) or aftermarket 4-wires sport button to the center console (SZM.)
9 to switch pin 2 is ground (Brown/Yellow)7 to switch pin 3 is signal (Yellow)27 to switch pin 5 goes to led light 2 power wire (E60 M5 only) (Blue/Yellow)8 to switch pin 1 goes to led light 1 power wire (Black/Yellow)4 goes to 12Volts power wire (Gray/Red) - Terminal 58G
Beforehand, plug a scanner like ISTA+, DeepOBD or Protools in order to make sure the EGS is recognized. Assert you can display clutch adaptations for example.
AUSWERTUNG_P_HW (Evaluate transmission Park/neutral signal from EGS)ABZUGSPERRE_PLOCK_C6 (Engine Start only with EGS in Neutral/Park). Normally this option is already inactive for the E60 LCIGETRIEBE_GAENGE from 6_gaenge to 8_gaenge (From 6 speed to 8 speed)EGS must be coded to factory-default.
N/ADZM_DISP_RPM wert_01 to wert_02 (Tachometer RPM Signal source)FDC_VERBAUT (Display Sport Mode) - If sport button is presentFDC_ID_MONITOR (Monitor Sport Mode) - If sport button is presentThe variables above are already set in case of S2TBA VO option
Considering the 8HP gear ratios, it is optional but recommended to change the differential to a lower ratio.
Knowing the F10 N52 differential ratio is 3.38 (wheels 245/45R18) and F30 320i 3.15 (wheels 225/45/R18)
You can calculate the correct Differential gear ratio in here
The sweet spot for a E60 LCI N52 vehicle is a ratio of 3.15, but it was never produced, thus it is recommended to fit one of the following:
3310 7 560591 (520d Auto or Any E60 Manual equipped with N52) 3310 7 565435 (Requires replacement of output drive flanges) 3310 7 555728 (Requires replacement of output drive flanges) 3310 7 560042 (Requires replacement of output drive flanges) 
Later on, you will have to use an EGS custom tune or simply BMW Tool32 to change the differential ratio information on the EGS tune, to whatever differential ratio installed on your car.
For 8HP45 equipped vehicles (Especially 1st generation), BMW added some vibration dampers.
In the context of this conversion, the user might optionally look at different vibration dampers and install the one with the corresponding dominant vibration
Go for this step only if drivetrain vibrations are felt after the swap (Especially when driving at 5th gear).
3350 6 852 835 3317 6 850 212 3350 6 861 489 Cruise control gets deactivated automatically and errors logged (DME, DSC, EGS), once the transmission shifts to the 8th gear.
| Code | Module | Description |
|---|---|---|
2F4C |
DME | EWS-DME. Message incorrect (Only in some cases) |
CF65 |
EGS | Message (Secured status for door sensors BN2000 1E1h) for (EGS_EL, PT-CAN) from (FRMFA, PT-CAN) |
5118 |
EGS | Interface DSC |
6F56
|
There is hopefully a tested community fix for the E90 platform, detailed in Here. It implies updating the DME program to the latest version (For the E60: 1214 7 602220 | For the E9x: 1214 8 613000) using WinkFP, applying a patch onto the MSV80 DME firmware using a reliable flasher like MSV80 QuickFlash and re-coding the DSC (DSC Coding Only for 2009+ E90 with MK60 DSC):
Set:C0F_GETRIEBE to wert_00 (Manual logic instead of automatc logic)
Set: C0F_AFH_HSA to wert_00 (Deactivation of Hill-brake Assist)
However on the E60 platform (EHB60 DSC):
There is no option to set the transmission logic to Manual and Setting:HHC to nicht_aktiv (Deactivation of Hill Hold Control)
would not get rid of the DSC error 6F56 as it is DME related (DME not sending Torque/Speed data when 8th gear is engaged).
Likely, another MSV80 DME patch is needed to send data frames message of engine torque and speed when 8th gear is engaged.
A similar patch is probably needed for the DSC to get rid of the 5118 error code.
As a last resort to get rid of the CF65 error code, flashing a custom EGS tune with that code deactivated, is a safe option.
The 8th gear not displayed in the E6x LCI instrument cluster (Kombi60), even with the latest firmware. only 1 to 7, as its firmware does not understand 8th gear CAN data frame. Surprisingly, the E70 cluster (04.2009+ 6210.9.236.810) is able to display the 8th gear.
Workaround 1: would be to fit a cluster from a petrol 8hp powered E70. The housing and mountings are the same.
The Cluster mileage and VIN must be matched to the car, then match-coded to the car (replicate the coding of the E60 cluster _VO, Variables_ onto the E70 cluster) and deactivate the following variables:
Deactivate:EMF_ID_MONITOR (Monitor Electronic parking identification)
Deactivate: EMF_ALIVE_ZAEHLER (Electronic parking alive counter)
The drawback of this workaround is that the E70 cluster does not read some data like coolant level, Washer fluid level, parking brake switch state and fuel level as the wiring is different.
In The E60 the above data goes directly to the cluster while in the E70, it goes to the junction box and then gets processed back to the cluster via CAN protocol
Notice the fuel tank input for the E70 is coded as CAN-BUS while for the E60 it is coded as ANALOG:
Option 2: Figure out how to Patch the KOMBI60 cluster after reverse-engineering of the E70 cluster firmware.
TODO: figure out how to simulate the E70 JBE module fuel level signal conversion or whether only proper coding could solve it
Option 3: CANChecked and AK Motion data displays claim to display transmission gear from Can BUS
XHP Flashtool OTS maps cannot be flashed to the retrofitted 8HP out of the box.
In order to do so, a secondary CAS3 ECU cloned to the original vehicle CAS and edited with the VIN of a 8HP45 equipped E70 N55 is needed. A custom thus expensive tune from XAutomotive is possible. Their standard OTS maps are supported only through their partnership with CanFormance CANTCU.Requesting A performance Map from BimmWorks tuning company is another option
Requesting OTS Maps from StageX company is another option
Requesting a Stage1/2 from Stagex-performance company may be a another option
