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Home >> BMW >> 2004 >> 545i Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> REMOVAL & INSTALLATION - 545i & 645Ci (GS6S53BZ SMG) >> Removal & Installation >> Manual Transmission >> Removal

Manual Transmission: Removal

  1. Disconnect battery. See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY.
  2. Remove front underbody protection. Release screws (1). See Fig 1 . Remove reinforcement plate.
    3. Fig 1: Removing Reinforcement Plate
    G00162766Courtesy of BMW OF NORTH AMERICA, INC.
  3. Remove complete exhaust system. See REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (N62).
  4. Remove oxygen sensors.
  5. Remove heat shields (1) and (2). See Fig 2 .
    6. Fig 2: Removing Heat Shields
    G00382256Courtesy of BMW OF NORTH AMERICA, INC.
  6. Pull plug (1) off pulse generator. See Fig 3 . Release screw (2) and remove pulse generator.
    7. Fig 3: Removing Pulse Generator
    G00382264Courtesy of BMW OF NORTH AMERICA, INC.
  7. Detach plug (1) from oil level sensor and unclip cable from fixtures. See Fig 4 .
    8. Fig 4: Detaching Plug From Oil Level Sensor
    G00382259Courtesy of BMW OF NORTH AMERICA, INC.
  8. Detach plug (1) from cable duct. See Fig 5 .
    9. Fig 5: Detaching Plug From Cable Duct
    G00382260Courtesy of BMW OF NORTH AMERICA, INC.
  9. Press in retaining lugs (1) with screwdriver (2) and remove cable duct (3). See Fig 6 . Tie wiring harness to one side.
    10. Fig 6: Removing Cable Duct
    G00382261Courtesy of BMW OF NORTH AMERICA, INC.
  10. Release screws (1) to support transmission. See Fig 7 .
    11. Fig 7: Releasing Transmission To Engine Screws
    G00382262Courtesy of BMW OF NORTH AMERICA, INC.
  11. Support transmission with Special Tools (00 2 030, 23 0 132, 23 0 131, 23 0 136) and (21 0 135). See Fig 8 .
    12. Fig 8: Supporting Transmission
    G00382265Courtesy of BMW OF NORTH AMERICA, INC.
  12. Unfasten screws (1) and nuts (2). See Fig 9 . Remove transmission cross-member.
    13. Fig 9: Removing Transmission Cross-Member
    G00382252Courtesy of BMW OF NORTH AMERICA, INC.
  13. Remove propeller shaft from transmission. Release center bearing. See REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT. Tie propeller shaft to one side.
  14. Disconnect plug connections (1) and (2). See Fig 10 . Release cable strap (3).
    15. Fig 10: Disconnecting Plug Connections
    G00382266Courtesy of BMW OF NORTH AMERICA, INC.
  15. Disconnect plug connections (1) and (2) and unclip cable from holder. See Fig 11 .
    16. Fig 11: Locating Plug Connections
    G00382267Courtesy of BMW OF NORTH AMERICA, INC.
  16. Detach plugs (4) from clutch travel sensor. See Fig 12 .
    17. Fig 12: Detaching Plugs From Clutch Travel Sensor
    G00382268Courtesy of BMW OF NORTH AMERICA, INC.
  17. Detach plug (1) from sensor. See Fig 13 .
    18. Fig 13: Detaching Plug From Sensor
    G00382269Courtesy of BMW OF NORTH AMERICA, INC.
    CAUTION: Do not allow the transmission to hang off from the transmission input shaft as this will deform the clutch plate.
  18. Unfasten screws. See Fig 14 .
    19. Fig 14: Locating Transmission Mounting Screws
    G00374671Courtesy of BMW OF NORTH AMERICA, INC.
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