23 23 507 Disassembling And Assembling All Synchronizing Mechanisms (S5D 260Z / 310Z / 320Z): Installation:

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.

Replace retaining ring (4).

Move 1st/2nd gear sliding sleeve in direction of 2nd gear. Position press-off supports on 1st gear wheel.

Fig 1: Moving 1st/2nd Gear Sliding Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Press following parts off output shaft:

Guide sleeve
Reverse gear wheel with synchronizer ring
Needle bearing
Bearing sleeve
1st gear wheel
Thrust washer

Pull off following parts:

Needle bearing
Synchronizer ring
Intermediate ring
Outer race

Fig 2: Pulling Off Needle Bearing, Synchronizer Ring And Intermediate Ring
Courtesy of BMW OF NORTH AMERICA, INC.

Detach 1st/2nd gear sliding sleeve.

CAUTION: Loose thrust pieces, balls and springs.

Lever out retaining ring (1).

Fig 3: Removing Retaining Ring & Spacer

Courtesy of BMW OF NORTH AMERICA, INC.

Remove spacer (2).

Replace retaining ring (1).

Position press-off supports on 2nd gear wheel.

Press guide sleeve, 2nd gear wheel with synchronizing mechanism and needle bearings off output shaft.

Fig 1: Pressing Off Guide Sleeve, 2nd Gear Wheel & Needle Bearings

Courtesy of BMW OF NORTH AMERICA, INC.

Assembling gear train:

Fit needle bearings and 2. gear wheel with recesses facing upwards.

Fig 2: Assembling Gear Train

Courtesy of BMW OF NORTH AMERICA, INC.

Attach synchronizing mechanism.

Consisting of:

Place the inner race (1), intermediate ring (2) with drives (3) in the recesses of the 1st gear wheel and synchronizer ring (4).

Fig 3: Attaching Synchronizing Mechanism

Courtesy of BMW OF NORTH AMERICA, INC.

Check 2nd gear synchronizing mechanism for wear.

Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer ring by hand.

Fig 4: Measuring Distance Between Gear Wheel And Synchronizer Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Specification: at least 0.9 mm

Actual new part distance: 1.1-1.6 mm.

When replacing, all three parts must be replaced at one time.

Heat guide sleeve to approx. 80°C (hot air blower).

Fit guide sleeve with long collar facing 2nd gear wheel.

Fig 5: Fitting Guide Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

When fitting, make sure driver lugs (5) of inner race are flush with recesses (6) on gear wheel.

In addition, driver lugs (7) on synchronizer ring must engage in grooves (8) of guide sleeve.

Press on guide sleeve with special tool 23 1 290 until firmly seated.

Fig 6: Pressing On Guide Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Install spacer (2).

Install retaining ring (1).

Retaining ring must be seated without play in groove; if necessary, replace spacer (1).

Spacers are available in different thicknesses

Sizes from 1.8 - 2.05 mm.

Fig 7: Installing Spacer And Retaining Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Insert 3 thrust pieces (1) and 3 pressure springs (2) in recess in guide sleeve.

Fig 8: Installing Thrust Pieces And Pressure Springs

Courtesy of BMW OF NORTH AMERICA, INC.

Fit 1st/2nd gear sliding sleeve with flat side facing upwards or with angled side facing 2nd gear wheel.

The three set-back or opened teeth must point to the springs.

Fig 9: Fitting 1st/2nd Gear Sliding Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Tilt thrust pieces (1) individually as far out of sliding sleeve until balls (3) can be placed on pressure springs.

Fig 10: Installing Balls

Courtesy of BMW OF NORTH AMERICA, INC.

Press balls (3) inwards. Simultaneously press thrust pieces into sliding sleeve.

Pull sliding sleeve uniformly upwards up to lock (neutral setting).

Check 1st gear synchronizing mechanism for wear.

Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer ring by hand.

Fig 11: Measuring Distance Between Gear Wheel And Synchronizer Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Specification: at least 0.9 mm

Actual new part distance: 1.1 - 1.6 mm.

When replacing, all three parts must be replaced at one time.

Place synchronizer ring (1), intermediate ring (2) and inner race (3) with driver lugs (4) in recesses (5) in guide sleeve.

Fig 12: Installing Synchronizer Ring, Intermediate Ring And Inner Race

Courtesy of BMW OF NORTH AMERICA, INC.

Fit needle bearing.

Fit 1st gear wheel with grooves (6) facing driver lugs (7).

Fig 13: Fitting Needle Bearing

Courtesy of BMW OF NORTH AMERICA, INC.

Heat thrust washer (9) and bearing bush (8) to approx. 80°C (hot air blower) and attach to output shaft, press on if necessary.

Fig 14: Identifying Thrust Washer And Bearing Bush

Courtesy of BMW OF NORTH AMERICA, INC.

Thrust washer with special tool 23 1 290.

Bearing bush with special tool 33 1 342.

Check reverse gear synchronizing mechanism for wear.

Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer ring by hand.

Specification: at least 0.5 mm

Actual new part distance: 0.7... 1.15 mm.

Fig 15: Measuring Distance Between Gear Wheel And Synchronizer Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Fit needle bearing and reverse gear wheel.

Fig 16: Fitting Needle Bearing And Reverse Gear Wheel

Courtesy of BMW OF NORTH AMERICA, INC.

Fit reverse gear synchronizer ring on reverse gear taper.

Fig 17: Installing Output Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Heat 5th/reverse gear guide sleeve to approx. 80°C (hot air blower). Fit output shaft with tapered end (1) facing upwards; if necessary, press on with special tool 33 1 342 until firmly seated.

Make sure driver lugs (3) engage in recess (2).

Insert spacer (5) and retaining ring (4).

Fig 18: Inserting Spacer And Retaining Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Retaining ring (4) must be seated without play in groove; if necessary, replace spacer.

Spacers are available in different thicknesses in sizes from 3.6- 4.0 mm.

Gently knock retaining ring inwards.

Insert 3 thrust pieces (1) and 3 pressure springs (2) in recess in guide sleeve.

Fig 19: Inserting Thrust Pieces And Pressure Springs

Courtesy of BMW OF NORTH AMERICA, INC.

Fit sliding sleeve with stepped side (1) facing reverse gear wheel.

The three set-back or opened teeth must point to the springs.

Fig 20: Fitting Sliding Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Tilt thrust pieces (1) individually as far out of sliding sleeve until balls (3) can be placed on pressure springs. Press balls (3) inwards. Simultaneously press thrust pieces into sliding sleeve.

Insert 5th gear synchronizer ring in sliding sleeve. Pull sliding sleeve uniformly upwards up to lock (neutral setting).

Fig 21: Installing Balls

Courtesy of BMW OF NORTH AMERICA, INC.

Check 5th gear synchronizing mechanism for wear.

Measure distance X between gear wheel and synchronizer ring.

In so doing, press down uniformly on the synchronizer ring by hand.

Specification: at least 0.75 mm

Actual new part distance: 0.95... 1.35 mm.

Fig 22: Measuring Distance Between Gear Wheel And Synchronizer Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Insert synchronizer ring.

Attach needle bearing and drive shaft to 5th gear wheel.

Fig 23: Attaching Needle Bearing And Drive Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Countershaft:

Replace 3rd/4th gear synchronizing mechanism.

Fit special tool 23 2310 on 3rd gear wheel.

Press bearing inner race (1), thrust washer, 4th gear wheel with needle bearing, synchronizing mechanism and 3rd gear wheel with needle bearing off countershaft.

Fig 24: Installing Bearing Inner Race

Courtesy of BMW OF NORTH AMERICA, INC.

Assembling:

Check 3rd/4th gear synchronizing mechanism for wear.

Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer ring by hand.

Specification: at least 0.75 mm

Actual new part distance: 0.95... 1.35 mm.

Fig 25: Measuring Distance Between Gear Wheel And Synchronizer Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Fit needle bearings and 3rd gear wheel.

Fig 26: Fitting Needle Bearings And 3rd Gear Wheel

Courtesy of BMW OF NORTH AMERICA, INC.

Pull 3rd/4th sliding sleeve off guide sleeve.

CAUTION: Loose balls, springs and thrust pieces.

Fig 27: Pulling Sliding Sleeves Off Guide Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Fit synchronizer ring on 3rd gear taper.

Fig 28: Fitting Guide Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Heat 3rd/4th gear guide sleeve to approx. 80°C (hot air blower).

Fit guide sleeve with long collar (1) facing 3rd gear wheel.

When fitting, make sure driver lugs (2) are flush with recesses on guide sleeve.

If necessary, press the guide sleeve on to fit tight with help of special tool 23 1 290.

Fig 29: Pressing On Guide Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Heat bearing inner race (3) to approx. 80°C (hot air blower) and attach to countershaft.

If necessary, press it on to fit tight with help of special tool 33 1 342

Fig 30: Installing Bearing Inner Race

Courtesy of BMW OF NORTH AMERICA, INC.

Insert 3 thrust pieces (1) and 3 pressure springs (2) in recess in guide sleeve.

Fig 31: Inserting Thrust Pieces And Pressure Springs

Courtesy of BMW OF NORTH AMERICA, INC.

Fit 3rd/4th gear sliding sleeve with stepped side (3) facing upwards.

The three set-back or opened teeth must point to the springs.

Fig 32: Fitting 3rd/4th Gear Sliding Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Tilt thrust pieces (1) individually as far out of sliding sleeve until balls (3) can be placed on pressure springs.

Press balls (3) inwards. Simultaneously press thrust pieces into sliding sleeve.

Fig 33: Installing Balls

Courtesy of BMW OF NORTH AMERICA, INC.

Insert 4th gear synchronizer ring (4) in recesses in guide sleeve.

Pull sliding sleeve uniformly upwards up to lock (neutral setting).

Fig 34: Inserting 4th Gear Synchronizer Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Fit needle bearing and 4th gear wheel.

CAUTION: The needle bearing has been selected by the manufacturer in accordance with a specific tolerance and is green in color.

Do not mix up with other needle bearings.

Fig 35: Fitting Needle Bearing And 4th Gear Wheel

Courtesy of BMW OF NORTH AMERICA, INC.

Heat thrust washer (2) and bearing inner race (1) to approx. 80°C (hot air blower) and attach to countershaft with collar (3) facing downwards.

If necessary, press them on to fit tight with help of special tool 23 1 160.

Fig 36: Installing Countershaft

Courtesy of BMW OF NORTH AMERICA, INC.