23 21 502 Removing And Installing Complete Drive And Output Shafts (S5D 260Z / 310Z / 320Z)

WARNING: This page is about a different car, the 2002 BMW M Roadster, 2002 BMW M Coupe, 2001 BMW M Roadster, and 2001 BMW M Coupe. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

00 1 490
23 0 020
23 0 100
23 0 490
23 1 050
23 1 160
23 2 150
23 2 250
23 2 260
23 2 270
23 2 280
23 2 290
23 2 293
23 2 300
23 2 320
23 2 330
23 2 340
23 2 350
23 2 360
23 2 370
23 2 380
33 1 150
33 1 301

Remove transmission.

Remove clutch release unit/lever. Refer to 21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER .

Unscrew drain plug.

Drain off oil.

Screw special tool 23 0 100 (transmission bracket) into hole for drain plug and secure.

Fig 1: Mounting Special Tool On Transmission Assembly Stand

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Mount special tool 23 0 100 on assembly stand 00 1 490.

Recycling:

Catch and dispose of escaping transmission fluid.

Observe country-specific waste-disposal regulations.

Release screws and pull out guide tube.

Fig 2: Locating Guide Tube Retaining Screws

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NOTE: Two covered removal holes (1) are located on end face of radial seal.

Fig 3: Identifying Covered Removal Holes

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Screw special tool 23 0 490 into one of the two removal holes.

Fig 4: Screwing Special Tool Into Removal Hole

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Withdraw radial seal from transmission housing with aid of impact weight.

Remove left bearing pin and screw for reverse gear pin in front housing section.

Fig 5: Removing Left Bearing Pin

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Remove reverse gear switch and right bearing pin in front housing section.

Fig 6: Removing Reverse Gear Switch And Right Bearing Pin

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Lever out retaining ring (1).

Remove sealing cover (2).

Fig 7: Removing Retaining Ring And Sealing Cover

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Remove pressure spring (3) and catch pin (4).

Fig 8: Removing Pressure Spring And Catch Pin

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Remove housing screws.

Fig 9: Removing Housing Screws

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Pull off front housing section with special tools 23 2 280 and 33 1 301.

Fig 10: Removing Front Housing Section With Special Tools

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CAUTION: Bearings or elements of the bearing brackets could be damaged while pulling off the front case section.

Catch pin for 5th/reverse gear falls out.

Always replace bearings and segments during removal.

Remove pressure spring (1) and thrust pin (2).

Remove roller bearing (3).

Fig 11: Removing Pressure Spring, Thrust Pin And Roller Bearing

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Withdraw shift shaft (4).

Fig 12: Removing Shift Shaft

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CAUTION: Needles on shift shaft.

Remove 5th/reverse gear shift arm towards top.

Remove 2 bearing pins on right.

NOTE: Bearing pins must be replaced.

Fig 13: Removing Bearing Pins On Right

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Remove 3 bearing pins on left.

NOTE: Bearing pins must be replaced.

Fig 14: Removing Bearing Pins On Left

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Remove locking lever (1) completely.

Remove pressure spring (2) and thrust pin (3).

Fig 15: Removing Locking Lever, Pressure Spring And Thrust Pin

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Remove screw (4).

Fig 16: Removing Screw

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Remove reverse gear wheel with needle bearings, thrust washer, pin and half shell.

Pierce sealing cover (5) on side.

Fig 17: Removing Sealing Cover

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Lever out sealing cover (5) in hole with a screwdriver.

Installation:

Replace sealing cover.

Engage a gear by hand.

Grip output flange with special tool 23 0 020.

Fig 18: Removing Output Flange With Special Tool

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Release screw (6).

CAUTION: Left-hand threads.

Remove washer (7).

Disengage selected gear again.

Grip output flange with special tool 23 0 020.

Fig 19: Releasing Collar Nut With Special Tool

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Release collar nut (1) with special tool 23 2 320.

Detach output flange with special tool 33 1 150.

Fig 20: Detaching Output Flange With Special Tool

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Compress gear train at 5th/reverse gear sliding sleeve with countershaft with special tool 23 2 250.

Fig 21: Compressing Gear Train At 5th/Reverse Gear Sliding Sleeve

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Attach special tool 23 2 370 to output shaft and countershaft.

Attach special tool 23 1 050 to housing sealing surface and center of special tool 23 2 370.

Fig 22: Attaching Special Tool To Output Shaft And Countershaft

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CAUTION: Use a piece of wood, plastic or similar on the sealing surfaces.

Press out gear train and countershaft uniformly.

When pressing out, make sure gear train and countershaft do not get jammed.

Installation:

The bearings or elements of the bearing brackets could be damaged while pressing out the drive and output shafts.

Always replace bearing and segments during removal.

Remove gear train with 1st/2nd and 3rd/4th gear shift arms and countershaft.

Fig 23: Removing Gear Train

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Installation:

Clean housing.

Drive out sealing cap (1 and 2) on rear housing section with a mandrel from inside to outside.

Fig 24: Driving Sealing Cap Out

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Installation:

Replace sealing cap.

Replace bearing (1) and (2) (output shaft, countershaft and retaining plates).

Fig 25: Replacing Bearings

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Lever out radial seal (3 and 4) for output and selector shafts.

Fig 26: Removing Radial Seal For Output And Selector Shafts

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Compress gear train at 5th/reverse gear sliding sleeve with countershaft. Use special tool 23 2 250.

Fig 27: Compressing Gear Train At 5th/Reverse Gear Sliding Sleeve With Countershaft

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Attach 3rd/4th gear shift arm with sliding blocks to 3rd/4th gear slide sleeve.

Rest shift arm on 3rd gear wheel of output shaft.

Connect shift arm with catch (1) in direction of drive shaft on left.

Fig 28: Connecting Shift Arm With Catch

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Insert gear train with shift arm in rear housing section.

Attach 1st/2nd gear shift arm with sliding blocks to 1st/2nd gear slide sleeve.

CAUTION: Connect shift arm with catch (1) in direction of drive shaft on left.

Attach special tool 23 2 330 to output shaft journal. Draw in output shaft with special tool 23 2 330 until firmly seated.

Fig 29: Attaching Special Tool To Output Shaft Journal

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When drawing in, make sure shift arms and countershaft do not get jammed, align if necessary.

Remove special tool 23 2 330.

Center 3rd/4th gear shift arm by hand with bore in housing. In this position, screw in bearing pins (2) in succession on left and right and then tighten down.

Fig 30: Tightening Bearing Pins

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Tightening torque, 23 31 1AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .

Oil sealing lip of radial seal.

Drive in radial seal (3) for output flange with special tool 23 2 300.

CAUTION: Use a plastic hammer to knock in.

Fig 31: Installing Radial Seal For Output Flange With Special Tool

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Heat output flange to approx. 80°C (hot-air blower).

Push output flange onto output shaft.

If necessary, drive on to fit tight with special tool 23 1 160.

Fig 32: Pushing Output Flange Onto Output Shaft

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Fit collar nut (1) with flat side pointing to output flange with screw retaining compound, refer to BMW Parts Service.

Fig 33: Securing Collar Nut With Drive Socket

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Grip output flange with special tool 23 0 020.

Secure collar nut with drive socket 23 2 320.

Tightening torque, 23 21 1AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .

Heat ball bearing inner race (2) for countershaft to approx. 80°C (hot-air blower).

Fig 34: Pressing Ball Bearing Inner Race With Special Tool

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Press on ball bearing inner race (2) with special tool 23 1 160 until firmly seated, drive on with gentle taps if necessary.

Install washer (3) and screw (4) with screw retaining compound, refer to BMW Parts Service.

CAUTION: Screw (4) has left-hand thread.

Fig 35: Installing Washer And Screw

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Remove special tool 23 2 250 from gear train.

Engage a gear.

Grip output flange with special tool 23 0 020.

Fig 36: Gripping Output Flange With Special Tool

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Tighten down screw (4).

Tightening torque, 23 11 10AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .

Disengage selected gear again.

Install sealing cap (1) and drive in with special tool 23 2 150 until flush.

Fig 37: Installing Sealing Cap And Drive In With Special Tool

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Coat half shell (2) with sealing compound, refer to BMW Parts Service, in area of screw bore and install.

Install pin (3), thrust washer (4), needle bearing (5) and reverse gear wheel (6) with collar (7) pointing to housing.

Coat collar of screw head with sealing compound, refer to BMW Parts Service.

Install screw (8) with screw retaining compound, refer to BMW Parts Service, but do not tighten down.

Fig 38: Installing Pin, Thrust Washer, Needle Bearing And Reverse Gear Wheel

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Install 5th/reverse gear shift arm with sliding blocks with catch (1) to left in 5th/reverse gear sliding sleeve.

Fig 39: Installing 5Th/Reverse Gear Shift Arm In Sliding Sleeve

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Insert locking lever (1) with long tongue (2) into slot of 5th/reverse gear shift arm.

Fig 40: Inserting Locking Lever With Long Tongue Into 5Th/Reverse Gear Shift Arm Slot

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Swivel locking lever (1) inwards and in so doing engage in recesses of 1st/2nd and 3rd/4th gear shift arms.

Fig 41: Engaging Recesses Of 1st/2nd And 3rd/4th Gear Shift Arms

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Center locking lever (1) by hand with bores.

Fig 42: Installing Bearing Pins On Left And Right

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Install bearing pins (2) and (3) on left and right and tighten down.

Tightening torque, 23 31 1AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .

Carry out movement check on locking lever.

Insert selector shaft (4) in horizontal position.

Apply grease to 4 rollers.

Fig 43: Inserting Selector Shaft In Horizontal Position

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Drive in radial seal (1) for selector shaft with special tool 23 2 260.

Fig 44: Driving In Radial Seal For Selector Shaft With Special Tool

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Secure selector shaft with special tool 23 2 270 in neutral position.

Fig 45: Securing Selector Shaft With Special Tool In Neutral Position

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Use a 8 mm bolt and cylindrical pin (2) from the shift joint or a suitable mandrel for holding the shift shaft.

Fig 46: Driving Out Sealing Cap For Locking Pin

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Clean front housing section.

Drive out sealing cap (3) for locking pin with a mandrel from inside to outside.

Installation:

Replace sealing cap.

Replace bearing of drive shaft and retaining segments (1). Refer to 23 21 805 REPLACING BEARINGS ON ALL TRANSMISSION SHAFTS (S5D 260Z / 310Z / 320Z) .

Remove retaining plates (1).

Fig 47: Removing Retaining Plates

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Insert magnets (4) in rear housing section.

Fig 48: Inserting Magnets In Rear Housing Section

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Attach roller bearing (5) with small diameter facing outwards.

NOTE: Coat needles with grease and press them in to avoid canting of the needles when mounting the front case section.

Clean housing sealing surfaces and coat with sealing compound, refer to BMW Parts Service.

Hold the 5th/reverse gear shift arm in horizontal position with a piece of string to make installation easier.

Fig 49: Holding 5th/Reverse Gear Shift Arm In Horizontal Position

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Attach front housing section up to centering pin (1).

Fig 50: Attaching Front Housing Section

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Insert 2 auxiliary screws M8 x 75 mm for centering housing opposing on left and right in rear housing section.

Install special tool 23 2 293 in front housing section.

Fig 51: Installing Special Tool In Front Housing Section

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Attach special tool 23 2 290 to drive shaft.

Fig 52: Attaching Support Shells To Drive Shaft

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Attach support shells (1) to drive shaft with conical side facing inwards.

Unscrewing the spindle presses the front case section on to the input shaft.

Press on front housing section only to such an extent that auxiliary cord can be removed again after installation of right bearing pin.

Fig 53: Installing Right Bearing Pin

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Center 5th/reverse gear shift arm (1) with bore and install right bearing pin (2). Do not tighten down.

NOTE: Replace bearing pin (2). Clean thread in housing.

Remove auxiliary cord.

Press on front housing section as far as it will go.

Remove special tool 23 2 290 completely.

Fig 54: Removing Special Tool From Selector Shaft

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Remove auxiliary screws from housing.

Clean front housing section to rear section.

Tightening torque, 23 11 1AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .

Remove special tool 23 2 270 from selector shaft.

Center 5th/reverse gear shift arm (1) with bore and screw in left bearing pin (2) by hand.

Fig 55: Tightening Bearing Pins On Left And Right

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Screw in left bearing pin (2) by hand.

Tighten down bearing pins (2) on left and right.

Tightening torque, 23 31 1AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .

NOTE: Replace bearing pin (2). Clean thread in housing.

Install bearing pin (3) for locking lever.

Fig 56: Installing Bearing Pin For Locking Lever

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This requires turning the transmission until bore (4) in the locking lever is aligned with the bore in the case.

In this position, turn the bearing pins (3) by hand and secure.

Tightening torque, 23 31 1AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .

Coat collar of screw head with sealing compound, refer to BMW Parts Service.

Install screw (1) for reverse gear pin with screw retaining compound, refer to BMW Parts Service.

Fig 57: Install Screw For Reverse Gear Pin

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Tighten both screws.

Tightening torque, 23 11 6AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .

Install catch pins (1 ... 3) with pressure springs in shift arms.

Fig 58: Installing Catch Pins With Pressure Springs In Shift Arms

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Drive in sealing caps (5 ... 7) with special tool 23 2 360.

Fig 59: Driving In Sealing Caps With Special Tool

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Replace catch pin (8) and pressure spring (9).

CAUTION: Note installation position of catch pin (8) (roller horizontal).

Fig 60: Replacing Catch Pin And Pressure Spring

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Install sealing cap (1) with special tool 23 2 350 in bore (2).

Push sealing cap (1) inwards as far as possible.

Fig 61: Installing Sealing Cap With Special Tool In Bore

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Install retaining ring (3) and press in with special tool 23 2 350 up to groove.

Fig 62: Installing Retaining Ring

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Check for correct seating of retaining ring (visual inspection).

Install reverse gear switch.

Install spacer (4).

Fig 63: Installing Spacer

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CAUTION: To prevent damage to drive shaft, attach special tool 23 2 380 to drive shaft while installing retaining ring (3).

Slide retaining ring (3) over special tool 23 2 380 and install in groove.

Retaining ring must be seated without play in groove.

Replace retaining ring with a matching retaining ring.

Retaining rings are available in various thicknesses.

Sizes: 2.2 ... 2.6 mm

Coat sealing lip of radial seal with ATF.

Fig 64: Attaching Special Tool To Drive Shaft

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Attach special tool 23 2 380 to drive shaft.

Push on radial seal (1) up to housing.

Remove special tool 23 2 380.

Drive in radial seal (1) with special tool 23 2 340 until flush.

CAUTION: Use plastic hammer to drive in.

Fig 65: Driving In Radial Seal

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Install guide tube.

Fig 66: Installing Guide Tube

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Tightening torque, 23 11 2AZ. Refer to MANUAL TRANSMISSION - TIGHTENING TORQUES .