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Automatic Transmission: Installation

WARNING: This page is about a different car, the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 740iL, 2001 BMW 740i, and 2001 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Oil cooler and lines must always be flushed before a replacement transmission is installed.
  1. To install, reverse removal procedure. If replacing transmission, fit shift lever, bracket for cable and retainers for oxygen sensor cable from old transmission to new transmission.
  2. Turn torque converter until Special Tool (24 2 300) is aligned with bore in drive plate. See Fig 1 . Attach input flange of automatic transmission to output flange on engine.
  3. Bore (1) in drive plate must be accessible from aperture in oil pan. See Fig 2 .
  4. Screw Special Tool (24 2 300) into the threaded bore (1). See Fig 3 .
  5. Check dowel sleeves. If necessary, remove dowel sleeves from transmission case and install in engine block. See Fig 4 . Replace damaged dowel sleeves.
  6. Tighten transmission-to-engine screws to specification. Always use washers when fitting screws. See Figure . See TORQUE SPECIFICATIONS  .
  7. Tighten torque converter-to-flywheel screws to specification. See Figure . See TORQUE SPECIFICATIONS  .
  8. If the impulse sensors are fitted to a new transmission, they must be reset. Note whether one or more shims are installed between the transmission housing and the pulse sensor. If one or more shims are installed, the distance between the pulse sensor and the pulse teeth of the increment wheel must be measured:
    • Turn the engine on the front central bolt so that a full pulse tooth (1) can be seen through the opening of the removed pulse sensor. Make sure that the pulse tooth (1) is exactly centered in the hole. See Fig 5 .
    • The depth to the pulse teeth of the flywheel must be determined with Special Tool (00 2 407). See Fig 6 . Note depth.
    • Measure depth (A) of pulse sensor. See Fig 7 . Deduct depth (A) of pulse sensor from depth of flywheel. This result is the gap dimension. Adjust a gap dimension of 0.53-0.57 mm with the shims. The dimension 0.55 mm should be achieved as exactly as possible in order to enable exact misfiring recognition and prevent pulse sensor from contacting pulse teeth.
  9. Preload center bearing in direction of travel to dimension (A) 2-4 mm. See Fig 8 . Center bearing must be aligned at right angles to propeller shaft. Tighten nuts of center mount-to-body to specification. See TORQUE SPECIFICATIONS  .
  10. Replace self-locking nuts of flexible disk-to-propeller shaft and transmission output flange. See Figure . When tightening screws, always brace screw and tighten down nut. This prevents flexible coupling from being subjected to torsion stress. Tighten to specification. See TORQUE SPECIFICATIONS  .
  11. Tighten crossmember screws to specification. See TORQUE SPECIFICATIONS  .
  12. Replace O-rings on oil lines. Tighten to specification. See TORQUE SPECIFICATIONS  .
  13. Brace clamping section (1) and loosen nut (2). See Fig 9 . Press shift lever (3) forwards (park setting). Press cable (4) in direction of arrow, then release again. Brace clamping section (1) and tighten nut (2) to specification. See TORQUE SPECIFICATIONS  .
  14. After completion of work, check transmission fluid level and top up if necessary.
Fig 1: Aligning Special Tool With Bore In Drive Plate
G00367891Courtesy of BMW OF NORTH AMERICA, INC.
Fig 2: Locating Bore In Drive Plate
G00367892Courtesy of BMW OF NORTH AMERICA, INC.
Fig 3: Aligning Torque Converter
G00056377Courtesy of BMW OF NORTH AMERICA, INC.
Fig 4: Checking Dowel Sleeves
G00367893Courtesy of BMW OF NORTH AMERICA, INC.
Fig 5: Centering Pulse Tooth In Hole
G00367897Courtesy of BMW OF NORTH AMERICA, INC.
Fig 6: Measuring Depth To Pulse Teeth
G00367898Courtesy of BMW OF NORTH AMERICA, INC.
Fig 7: Measuring Depth Of Pulse Sensor
G00367899Courtesy of BMW OF NORTH AMERICA, INC.
Fig 8: Removing/Installing Center Bearing
G00107761Courtesy of BMW OF NORTH AMERICA, INC.
Fig 9: Adjusting Shift Lever
G00367894Courtesy of BMW OF NORTH AMERICA, INC.
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