Removing and Installing Transmission (S5D 200G, S5D 250G, M52TU/M54)

23 00 022 Removing and installing transmission (S5D 200G, S5D 250G, M52TU/M54)

Special tools required:
^ 001 450
^ 118022
^ 24 0 1 70

Caution: After completion of work, check transmission fluid level. Use only approved transmission fluid. Failure to comply with this instruction will result in serious damage to the transmission.

Necessary preliminary tasks:
^ Disconnect battery
^ Remove reinforcement plate and underbody protection
^ Remove the entire exhaust system
^ E46 only: Remove heater bulkhead
^ E46 only: Remove intake hood

Remove heat shield (1).

E46 only: Release screws and remove exhaust bracket (1).

Z4 only: Release screws and remove exhaust bracket (1).

Support transmission from underneath. Release screws and remove cross-member (1). Tightening torque: 23 71 1AZ/2AZ

Unfasten screws. Tightening torque: 26 11 1AZ;Universal joint to propeller shaft and transmission
M10 8.8 48 Nm
M10 10.9 64 Nm

Installation:
Replace self-locking nuts.

Grip propeller shaft and release nuts. Tightening torque: 26 11 6AZ; center mount to body 21 Nm
Bend propeller shaft downwards on center bearing. Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.

Installation (except E46 Compact and Z4): Detach masking tape from butylene tape on both sides. Attach butylene tape (1)* to outside of center bearing (2).
^ Sourcing reference: BMW Parts Service

Caution: Remove any butylene tape already fitted on center bearing. Clean adhesive area on center bearing and on body. Then coat adhesive area on body with mineral oil (to enable the sticky butylene tape to feed easily into the propeller shaft tunnel). This prevents any deformation of the butylene tape.

Installation (except E46 Compact and Z4):
Press center bearing (2) into transmission tunnel.

Lower transmission.
E46 only:
Lower until cylinder head touches end wall. Suspend special tool 11 8 022 from left and right control arms.

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

Tighten down knurled screws until special tool fits tightly with engine oil sump.

Caution: Relieve tension on clutch slave cylinder slowly when removing; otherwise air will be drawn in through sealing sleeve.

Release nuts and remove clutch slave cylinder. Pressure pipe remains connected. Tightening torque: 21 52 5AZ; Slave cylinder to clutch housing or transmission case 22 Nm

Detach locking clamp.

Pull shift rod (1) out of shift rod joint (2) and remove shims (3).

Installation:
Grease shift rod pin (4) (grease, sourcing reference: BMW Parts Service).
Large contact surface of shims (3) must rest on shift rod joint (2).

Use a screwdriver to lift out spring (1) from the lug (2) on the housing and swivel upwards.

Remove bearing pin (1).

Installation:
Grease bearing pin (1) (grease, sourcing reference: BMW Parts Service).

Detach cable plug (1) from reverse gear switch. If necessary, release cable from fixtures.

Support transmission with workshop hoist. Unfasten screws. Tightening torque: 23 00 1AZ

Caution: Do not allow the transmission to hang from the transmission input shaft during removal and installation as this will deform the clutch plate.

Pull out transmission towards rear as far as possible, rotate approximately 10° counterclockwise and remove.

Subsequent work on transmission:
Support transmission with special tool 24 0 170 on assembly stand 00 1 450

Installation:
Pay attention to adapter sleeves (1 and 2), replace if necessary. Ensure correct position of cover plate.

Installation:
Remove release unit and release lever, clean and apply grease to relevant points.

Installation:
Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, replace clutch plate. Check clutch plate for friction rust in taper splines and replace if necessary.

Mechanically remove old grease and lining abrasion from the taper splines of the clutch disk (with a cloth).

Then, to grease the taper splines, apply a thin uniform layer of new grease (sourcing reference: BMW Parts Service) with a brush to the entire area of the taper splines. Also in taper groove and on guide pin.