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Home >> Mini >> 2010 >> Cooper S, 2D Hatchback, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 193 (REMOVAL & INSTALLATION - 545I & 645Ci (GS6-53BZ)) >> Removal & Installation >> Manual Transmission >> Removal

Manual Transmission: Removal

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.
  1. Disconnect battery. See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY.
  2. Remove underbody protection at front and rear. Release screws (1). See Fig 1 . Remove reinforcement plate.
  3. Remove exhaust system after catalytic converter. See REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (N62).
  4. Remove oxygen sensors.
  5. Remove heat shields (1) and (2). See Fig 2 .
  6. Detach plug (1) from reversing light switch. See Fig 3 . Release cable from retainers.
  7. Pull plug (1) off pulse generator. See Fig 4 . Release screw (2) and remove pulse generator.
  8. Detach plug (1) from oil level sensor and unclip cable from fixtures. See Fig 5 .
  9. Detach plug (1) from cable duct. See Fig 6 .
  10. Press in retaining lugs (1) with screwdriver (2) and remove cable duct (3). See Fig 7 . Tie wiring harness to one side.
  11. Release screws (1). See Fig 8 .
  12. Supporting transmission: support with Special Tools (23 0 136, 23 0 131, 23 0 132) and (00 2 030). See Fig 9 .
  13. Release screws (1) and nuts (2) and remove transmission cross-member. See Fig 10 .
  14. Remove propeller shaft from transmission. Release center bearing. See REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT. Tie propeller shaft to one side.
    15. NOTE: Pressure line of clutch slave cylinder remains connected.
  15. Slowly relieve tension on clutch slave cylinder otherwise air is drawn in through sealing sleeve. Release nuts and remove clutch slave cylinder. See Fig 11 .
  16. Lever out retainer (1). See Fig 12 . Disengage shift rod (2).
  17. Release and remove bearing pins (1) in direction of arrow. See Fig 13 .
  18. Lift out shift arm (1). See Fig 14 .
    19. CAUTION: Do not allow the transmission to hang off from the transmission input shaft as this will deform the clutch plate.
  19. Unfasten screws. See Fig 15 . Pull out transmission towards rear and remove.
Fig 1: Removing Reinforcement Plate
G00162766Courtesy of BMW OF NORTH AMERICA, INC.
Fig 2: Removing Heat Shields
G00382256Courtesy of BMW OF NORTH AMERICA, INC.
Fig 3: Disconnecting Plug From Reversing Light Switch
G00382257Courtesy of BMW OF NORTH AMERICA, INC.
Fig 4: Removing Pulse Generator
G00382258Courtesy of BMW OF NORTH AMERICA, INC.
Fig 5: Detaching Plug From Oil Level Sensor
G00382259Courtesy of BMW OF NORTH AMERICA, INC.
Fig 6: Detaching Plug From Cable Duct
G00382260Courtesy of BMW OF NORTH AMERICA, INC.
Fig 7: Removing Cable Duct
G00382261Courtesy of BMW OF NORTH AMERICA, INC.
Fig 8: Releasing Transmission To Engine Screws
G00382262Courtesy of BMW OF NORTH AMERICA, INC.
Fig 9: Supporting Transmission
G00382251Courtesy of BMW OF NORTH AMERICA, INC.
Fig 10: Removing Transmission Cross-Member
G00382252Courtesy of BMW OF NORTH AMERICA, INC.
Fig 11: Removing Clutch Slave Cylinder
G00374665Courtesy of BMW OF NORTH AMERICA, INC.
Fig 12: Disconnecting Shift Rod
G00382244Courtesy of BMW OF NORTH AMERICA, INC.
Fig 13: Removing Bearing Pins
G00382263Courtesy of BMW OF NORTH AMERICA, INC.
Fig 14: Lifting Out Shim Arm
G00382254Courtesy of BMW OF NORTH AMERICA, INC.
Fig 15: Locating Transmission-To-Engine Screws
G00367889Courtesy of BMW OF NORTH AMERICA, INC.
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