28 00 001 Removing and installing twin-clutch gearbox (GS7D36SG) (N54, N55)

Special tools required:

IMPORTANT: To prevent heavy damage to the engine block, the protruding thread of the transmission bolts absolutely must be checked for damage and corrosion before removal .
If there are signs of corrosion, the rust must be removed and the threads must be cleaned before removal .
Replace rusted, damaged screws.

Failure to comply with this instruction will result in serious damage to the engine block and transmission.

IMPORTANT: Before the gearbox is removed, it is imperative that a readout is taken of the specific gearbox data status using ISTA/P .
Twin-clutch gearbox must be shifted to position "N" before removal.
Changing gears is only possible with engine running!
After completion of work, check transmission oil level. See 28 00... CHECKING/TOPPING UP OIL LEVEL IN TWIN-CLUTCH GEARBOX (GS7D36SG) .
Use only the approved transmission oil. See DUAL-CLUTCH TRANSMISSION -- OPERATING FLUIDS .

Failure to comply with this requirement will result in serious damage to the twin-clutch gearbox!

Apply a thin coating of "MI-Setral-43N" grease to transmission input shaft.

IMPORTANT: Aluminum screws/bolts must be replaced each time they are released .
Aluminum screws/bolts are permitted with and without color coding (blue).
For reliable identification:
Aluminum screws/bolts are not magnetic .
Jointing torque and angle of rotation must be observed without fail (risk of damage) .
In vehicles with an N54/N55 engine from production date 09/2012, only steel bolts are installed.

Necessary preliminary tasks

Read out the gearbox data status via ISTA/P for the gearbox to be replaced.
Shift transmission to position "N".
Disconnect the battery . See 12 00... NOTES FOR DISCONNECTING AND CONNECTING BATTERY or 61 20 900 DISCONNECTING AND CONNECTING BATTERY EARTH LEAD .
Remove underbody protection . See 51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION or 51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION at front and rear.
Remove complete exhaust system . See 18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (N54) or 18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (N55) .
Support engine with jack when removing gearbox

Release screw (3).

Remove holder (4).

Slacken nut (5).

Remove holder (6).

Release screws (1).

Remove heat shield (2).

Fig 1: Identifying Heat Shield Holder, Screw And Nut

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Disconnect connectors (1) and release leads.

Unfasten screws (2).

Remove cover plate (4).

Release aluminum bolt (3) on right next to cable retaining plate.

Aluminum screws must be replaced.

Tightening torque: 25 Nm (angle of rotation 130 °) .

Fig 2: Identifying Transmission Cover Plate, Connector And Aluminum Bolt

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Release screw (1).

Unlock retainer (2).

Release cable from lever and holder.

Fig 3: Identifying Transmission Cover Screw And Retainer

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Supporting transmission

Support transmission with special tools 23 4 050 , 00 2 030 .

Secure transmission to mounting with tensioning strap (1).

Tasks are described in Gearbox holder. See 23... UNIVERSAL BMW TRANSMISSION TAKE-UP .

After completion of work, check transmission fluid level. See 28 00... CHECKING/TOPPING UP OIL LEVEL IN TWIN-CLUTCH GEARBOX (GS7D36SG) .

Fig 4: Supporting Transmission Using Special Tools

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Unfasten screws (1) and nuts (2).

Remove transmission cross-member.

Tightening torque: 22 32 3AZ/4AZ .

Fig 5: Identifying Transmission Cross-Member Screws And Nuts

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REMOVE propeller shaft from transmission.
Release center mount.
Note:
Bending the propeller shaft by an excessive angle can cause premature damage to the joint/propeller shaft!
Tie up propeller shaft to underbody.

Release screw (1).

Disconnect hydraulic lines (2) to transmission oil cooler.

Seal off pipes and connection holes on gearbox with plugs.

Installation note:

Replace sealing rings.

Fig 6: Identifying Hydraulic Lines Screw

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Release nut (1) and bracket from transmission oil lines on oil sump.

Fig 7: Identifying Transmission Oil Lines Nut

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Lower transmission
Unlock central transmission plug (1) by turning and disconnect.
Do not touch pins.
Release cable from brackets.

Repair work is described in NOTES ON MECHATRONICS .

IMPORTANT: Read and comply with important note.

Installation note:

Pay attention to routing and length of wiring harness.

Fig 8: Turning Central Transmission Plug

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Insert special tool 24 2 390 in sealing cup (1).

Fig 9: Inserting Special Tool (24 2 390) In Sealing Cup

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Release screws.

In vehicles with an N54/N55 engine from production date 09/2012, only steel bolts are installed.

Installation note:

Observe screw fastening sequence without fail.

Tightening torque: steel screws

M8x50 : 19 Nm
M10 : 38 Nm
M12 : 66 Nm

Aluminum screws must be replaced.

Tightening torque and angle of rotation, aluminum screws: 25 Nm (angle of rotation 130 °).

Fig 10: Transmission Housing Bolts Tightening/Loosening Sequence

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Installation note:

Tighten down screws/bolts to specified torque.

Special angle-of-rotation tool 00 9 120 with magnet 00 9 130 .

Secure to vehicle underbody and screw down aluminum screws/bolts in accordance with angle of rotation.

Angle of rotation 28 00 1AZ.

Fig 11: Tightening Vehicle Underbody Screws/Bolts

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Installation note:

Apply a thin coating of "MI-Setral-43N" grease to transmission input shaft.

BMW part number EU: 83 23 2 152 082

BMW part number USA: 83 23 2 152 081

Check that fitting sleeves are correctly fitted.

Replace damaged fitting sleeves.

Fig 12: Identifying Transmission Input Shaft Sleeves

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