Manual Transmission

Necessary preliminary tasks:

• Disconnect battery. See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
• Remove front underbody protection.
• Remove reinforcement plate. See REINFORCEMENT PLATE .
• Remove complete exhaust system. For 325i and 325Ci, see REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (M54) . For Z4, see REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (M54) .

Remove heat shield (1). See Fig 1.

Fig 1: Removing First Heat Shield

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Remove heat shield (1). See Fig 2.

Fig 2: Removing Second Heat Shield

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Release nuts and remove heat shield (1) from expansion tank. See Fig 3.

Fig 3: Removing Heat Shield From Expansion Tank

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E85 only: release screws and remove exhaust bracket (1). See Fig 4. To install, tighten screws to specification. See TORQUE SPECIFICATIONS .

Fig 4: Removing Exhaust Bracket (Z4)

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Release screws to support transmission. See Fig 5.

Fig 5: Locating Transmission To Engine Screws

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Supporting transmission: support transmission with Special Tools (00 2 030, 23 0 132, 23 0 131, 23 0 134) and (21 0 135). See Fig 6.

Fig 6: Supporting Transmission

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Unfasten screws (1) and nuts (2). See Fig 7. Remove transmission cross-member. To install, tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Fig 7: Removing Transmission Cross Member

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Remove propeller shaft from transmission. Release center bearing. Tie propeller shaft to one side. For 325i and 325Ci, see REMOVING AND INSTALLING PROPELLER SHAFT (CARDAN UNIVERSAL JOINT) COMPLETELY . For Z4, see REMOVING AND INSTALLING PROPELLER SHAFT (CARDAN UNIVERSAL JOINT) COMPLETELY .

Release screw (1). See Fig 8.

Fig 8: Locating Screw

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Disconnect plug connections (1) and (2). Release cable strap (3). See Fig 9.

Fig 9: Disconnecting Plug Connections

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Disconnect plug connections (1) and (2) and unclip cable from holder. See Fig 10.

Fig 10: Locating Plug Connections

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Detach plugs (4) from clutch travel sensor. See Fig 11.

Fig 11: Detaching Plugs From Clutch Travel Sensor

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Detach plug (1) from sensor. See Fig 12.

Fig 12: Detaching Plug From Sensor

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Unfasten screws. See Fig 13. To install, tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Fig 13: Locating Transmission Mounting Screws

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Installation: check that dowel sleeves are correctly seated. See Fig 14. Replace damaged dowel sleeves. Ensure correct position of cover plate.

Fig 14: Checking Dowel Sleeves

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Installation: check lubrication of transmission input shaft for sticky consistency. See Fig 15. If grease is sticky, replace clutch plate. Check clutch plate for friction rust in taper splines and replace if necessary. Remove any grease and lining abrasion from taper splines of clutch plate by mechanical means (with a cloth).

Fig 15: Checking Lubrication Of Transmission Input Shaft

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Installation: greasing specification:

• Remove and clean release bearing and release lever.
• Push on Grease Scraper Ring (21 2 221) as far as it will go. See Fig 16.
• Grease splines (1) of input shaft with a brush.
• Detach grease scraper ring.

Fig 16: Locating Grease Scraper Ring

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To complete installation, reverse removal procedure.