Repair Procedure

Correction:





Procedure:
All Models (pertains to both procedures A and B)





Switch Identification

1. Ignition must be switched off.

2. Engage reverse gear.

3. Raise vehicle on hoist.





4. Determine if switch is involved in campaign; refer to previous drawings. If switch is involved in campaign and the production code is not visible with the switch installed, switch must be removed for determination of production code.

CAUTION!

- Extreme care should be exercised when removing the switch so that the pin does not shatter when the switch is removed.

- When handling the removed reverse switch, do not point the switch pin (plunger) end in the direction of other persons. As a precaution, switches in the affected production range should have adhesive tape wrapped around the switch pin end after removal.

5. Continue with procedure A or B based on transmission application.

Procedure A (325i/is, 525i as of 7-2-92 with Getrag transmission)

1. If switch production code is other than 262 or 272, original switch need not be removed from transmission. Reinstall original switch if removed for inspection of production code.

2. If switch production code is 262 or 272, switch is to be replaced. Remove any broken fragments of switch readily accessible through switch mounting boss.

Procedure B (525i built up through 7-1-92 with ZF transmission)

1. If switch production code is other than 262 or 272, original switch need not be removed from transmission. Reinstall original switch if removed for inspection of production code.

2. If switch production code is 262 or 272, switch is to be replaced. Analysis of the removed switch will determine further action. If removed switch is intact, it is only necessary to install a new switch. If removed switch is broken, proceed as follows.

3. Drain transmission fluid through a finely meshed screen (i.e. a colander, available locally). Retrieve any fragments from the sump through the drain hole. The switch pin and spring will likely be found near the magnet in the transmission sump.

4. If the switch's spring is retrieved unbroken and the switch pin has only minor fractures (not deformed), then the transmission can be reused. Install the new switch, replace drain plug, and fill with Dexron II ATF.

5. If fragments of the spring are found in the oil draining screen or in the transmission sump, the transmission is to be replaced due to the possibility of gear tooth damage. In normal circumstances, the switch pin cannot penetrate between the gear teeth.

6. Replace the transmission if neither the spring or switch pin can be found.

7. Transmissions replaced should be returned together with the reverse switch and any fragments found once the Warranty Parts Return Tag prints out at the dealership. Please include the following note in the comments section of the return parts tag: "Reverse Switch - Fractured Tappet."

Parts Information:
Parts stock at the PDC has been purged of defective switches. Please check your dealership's stock and return defective switches as per established procedure.

Part Description Part Number Quantity Required
Reverse Switch 23 14 1 221 706 1