Manual Transmission: Installation

WARNING: This page is about a different car, the 2005 BMW 645Ci, 2005 BMW 545i, 2004 BMW 645Ci, and 2004 BMW 545i. However, it is still accessible from the selected car via links, so may be relevant.

Check that dowel sleeves are correctly seated. See Fig 1 . Replace damaged dowel sleeves. Ensure correct position of cover plate.

Fig 1: Checking Dowel Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.

Check lubrication of transmission input shaft for sticky consistency. See Fig 2 . 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 2: Checking Lubrication Of Transmission Input Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Remove and clean release bearing and release lever. Push on grease Scraper Ring (21 2 240) as far as it will go. See Fig 3 . Grease splines (1) of input shaft with a brush. Detach grease scraper ring.

Fig 3: Locating Grease Scraper Ring

Courtesy of BMW OF NORTH AMERICA, INC.

To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . After completing work:
- Perform adaptation using DIS Tester, refer to Service Functions in DIS Tester (Teach in transmission).
- Check gear oil level. Use only the approved transmission fluid.
- Check fluid level in hydraulic system.
- Read out fault memory and clear entered faults.
Failure to comply with this requirement will result in serious damage to the manual transmission.