A5S 360R/390R 2WD Transmission

Remove Automatic Transmission (A5S 360R/390R, A4S 200R)

Note: After completion of work, check transmission fluid level.

Disconnect battery.

Caution:
Use only the approved transmission fluid in this automatic transmission.
Failure to comply with this requirement will result in serious damage to the automatic transmission!

Remove intake hood (1).

Release fan cowl (1) and pull a little upwards.

Remove microfilter housing (1) and heater bulkhead behind it.

Caution: The section "Remove reinforcement plate" contains important installation instructions.

Note: Reinforcement plate is fitted in:
- Coupes from 11/99
- All convertibles
- All E46 models without 4WD from 12/2000

Remove reinforcement plate.

Remove engine underguard (1).

Release screws.

Remove front end reinforcement.

Note:
Remove complete exhaust system.

Remove heat shield (1).

Grip clamping sleeve (1). Release nut (2).

Installation:

Adjust selector lever.

Grip cable (1) at hexagon (2).

Release nut (3).

Pull cable (1) out of holder.

Support transmission with special tools 00 2 030 24 5 301/24 5 305.

Release screws.
Tightening torque, All = 21 Nm.

Remove cross-member (1).

Release screws.
Tightening torque,
M14 140 Nm
M12 10.9 100 Nm.

Installation:
Replace self-locking nuts.

Grip propeller shaft.

Release nuts.
Tightening torque,Center mount = 21 Nm.

Bend propeller shaft downwards at center bearing (1).

Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.

Installation:
Pull off cover tape from butylene tape on both sides.
Stick butylene tape (1) to outside of center bearing (2).

Caution: Remove butylene tape already attached to center bearing. Clean adhesive area on center bearing and on body. Then coat adhesive area on body with mineral oil. This coating with oil is necessary to facilitate insertion of the sticky butylene tape in the propeller shaft tunnel. This prevents the butylene tape from being deformed.

Installation:
Press center bearing (2) into transmission tunnel.

Lower transmission until cylinder head touches bulkhead.

Suspend special tool 11 8 022 from left and right control arms.

Caution: Position special tool so that engine oil sump is securely resting on special tool.

Tighten down knurled screws until special tool rests against engine oil sump.

Unlock and remove cable connector (1).

Unclip cable from transmission housing.

Release screw (1).

Withdraw hydraulic lines (2) to oil cooler from transmission housing.

Installation:
Replace sealing rings.

Remove cover.

Release retaining screws of torque converter (3x) with special tool 24 1 110.
Tightening torque, Torque converter to flywheel = M8 thread 26 Nm, M10 thread 45 Nm - 49 Nm.

Installation:
Use only original screws.

Protect torque converter from slipping out. To do so, insert special tool 24 4 131/24 4 135 in opening in transmission housing.

Clamp torque converter.

Release screws.

Pull off transmission from engine towards rear and lower it.

Installation:
Pay attention to adapter sleeves (1 and 2).

If necessary, withdraw adapter sleeves from transmission housing.

Insert new adapter sleeves into engine block.

Caution: When joining up engine and transmission, ensure ease of movement of torque converter.

Installation:
The sheet metal flywheel is equipped with three recesses for the torque converter retaining lugs.
When joining together engine and transmission, the three retaining lugs on the torque converter must be aligned with the three recesses in the sheet metal flywheel.
Failure to comply with this requirement leads to secondary damage on the automatic transmission.
The torque converter or engine is not able to spin and would cause damage.

Installation:
Bore on driver must point to center of aperture in cover plate.

Installation:
Twist torque converter on transmission until bores on lugs point to center of bore on flywheel.

Screw special tool 24 2 300 into lug.

Installation:
Raise automatic transmission until bore on driver is reached.
Carefully insert transmission into bore on driver with special tool 24 2 300.
Flange transmission housing to engine.
Remove special tool 24 2 300 from lug towards front.