Removing and installing twin-clutch gearbox (GS7D36SG): Notes

Special tools required:

00 2 030
00 9 120
00 9 130
23 4 050
24 2 390

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 repair work, check TRANSMISSION OIL LEVEL .
Use only the approved transmission oil.

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.

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 .
Remove IGNITION COIL COVER .
Remove underbody protection at front and rear. Refer to REMOVING AND INSTALLING/REPLACING UNDERBODY PROTECTION (FRONT) and REMOVING REFITTING/REPLACING REAR ENGINE UNDERCOVER .
Remove REINFORCEMENT PLATE .
Remove complete EXHAUST SYSTEM .
Remove propeller shaft. Refer to the appropriate procedure:
Support engine with jack when removing gearbox

Removal:

Remove gasket (1).

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Release and unplug connectors (1) from brackets.

Release and disconnect the cable (2) from brackets.

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Release screws (1).

Remove holder (2).

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Release screws (1).

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Release cable (1) from bracket.

Unscrew nuts (2).

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Slacken nut (1).

Release the ground cable (2) from the transmission.

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Release screw (1).

Disconnect hydraulic lines (2) to transmission oil cooler.

Seal off pipes and connection holes on gearbox with plugs.

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Release screw (1).

Unlock retainer (2).

Release the cable from the lever and guide.

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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 .

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Release screws (1).

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Lower transmission
Unlock central transmission plug (1) by turning and disconnect.
Do not touch pins.
Release cable from brackets.
Pay attention to the routing and length of the wiring harness.

Operations are described in:

NOTES ON MECHATRONICS .

IMPORTANT: Read and comply with important note.

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

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Release screws (1).

Unflange transmission.

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Installation:

Check that fitting sleeves (1) are correctly seated.

Replace damaged fitting sleeves.

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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

Transmission flange-mount.

Insert screws (1) and tighten.

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Remove special tool 24 2 390.

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Lock the central transmission plug (1) by turning.

Do not touch pins.

Fasten the cable in the bracket.

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Attach holder (2).

Insert screws (1) and tighten.

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Insert screws (1) and tighten.

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Observe screw fastening sequence without fail.

Tightening torque 28 00 1AZ .

Fig 1: Transmission Flange - Mount Screws Tightening Sequence

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Insert screws (1) and tighten.

Tightening torque 22 32 3AZ .

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Remove the transmission jack.

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Install the cable.

Lock the fuse (2).

Insert screw (1) and tighten down.

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Parts : Replace sealing rings.

Install the hydraulic lines (2) to the transmission oil cooler.

Insert screw (1) and tighten down.

Tightening torque: 17 22 1AZ .

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Fit nut (2) and tighten.

Fasten the cable (1) in the bracket.

Tightening torque: 18 20 1AZ .

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Install the ground cable (2) to the transmission.

Position nut (1) and tighten.

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Install the cable (2) in the bracket.

Lock connector (1) and install in brackets.

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Install gasket (1).

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Required follow-up work:

Install REINFORCEMENT PLATE .
Install propeller shaft. Refer to the appropriate procedure:
Completely install EXHAUST SYSTEM .
Install front and rear underbody protection. Refer to REMOVING AND INSTALLING/REPLACING UNDERBODY PROTECTION (FRONT) and REMOVING REFITTING/REPLACING REAR ENGINE UNDERCOVER .
Install IGNITION COIL COVER .
Connect the BATTERY .
Read-in the transmission data status via ISTA/P of the replaced transmission