Removal & Installation

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CAUTION: Use only the approved gear oil in this manual transmission. Failure to comply with this requirement will result in serious damage to the transmission.

NOTE: After completion of work, check transmission oil level. See SERVICING - M/T .

Disconnect battery, grounding strap to body. See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY.

Remove center muffler. See REPLACING INTERMEDIATE MUFFLER (M62, M54). Remove heat shield at front right. Remove heat shield at rear.

CAUTION: Reinstall reinforcement plate. Driving without reinforcement plate is not permitted.

Unscrew bolts (1, 2). Remove reinforcement plate. See Fig 1 . Installation: tighten bolts (2) to specification. See TORQUE SPECIFICATIONS . Remove engine underguard at front.

Fig 1: Locating Reinforcement Plate Bolts

G00160910

Courtesy of BMW OF NORTH AMERICA, INC.

Detach stabilizer bar and slide forwards. See STABILIZER .

Remove and install front propeller shaft. See REMOVING AND INSTALLING FRONT PROPELLER SHAFT.

Release screws and remove exhaust bracket (1). See Fig 2 .

Fig 2: Removing Exhaust Bracket

G00374738

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws. See Fig 3 . Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Fig 3: Locating Transmission To Engine Screws

G00382245

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Observe side markings.

Preparing transmission mount, Special Tool (23 0 130): to do so, bolt Special Tool (23 0 133) (3) to Special Tool (23 0 131) (1) and (23 0 132) (2). See Fig 4 .

Fig 4: Preparing Transmission Mount

G00382274

Courtesy of BMW OF NORTH AMERICA, INC.

Support transmission and transfer case with Special Tool (00 2 030) and (23 0 130). See Fig 5 .

Fig 5: Supporting Transmission & Transfer Case

G00382275

Courtesy of BMW OF NORTH AMERICA, INC.

Unclip cable from transmission. Release screws and remove cross-member (1). See Fig 6 . Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Fig 6: Removing Transmission Cross-member

G00374730

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Do not let propeller shaft fall into joints. Joints and rubber sleeve can be damaged on constant-velocity joint. See Fig 7 .

Release screws. See Fig 8 . Upon installation: replace self-locking nuts. When tightening screws down: grip each screw and tighten down nut. This prevents the flexible disk from being subjected to torsion stress. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Fig 7: Removing Propeller Shaft Mounting Screws

G00367882

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 8: Locating Screws Of Flexible Disk

G00374664

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Exhaust manifold must not rest on stabilizer bar.

Grip propeller shaft and release nuts. See Fig 9 . Bend propeller shaft downwards at center bearing (1). Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody. Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS . Lower transmission.

Fig 9: Removing Center Mount

G00367858

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Slowly relieve tension on clutch slave cylinder during removal as otherwise air will be drawn in through sealing sleeve.

Release nuts and remove clutch slave cylinder. See Fig 10 . Pressure line remains connected.

Fig 10: Removing Clutch Slave Cylinder

G00374665

Courtesy of BMW OF NORTH AMERICA, INC.

Detach cable plug (1) from reverse gear switch. See Fig 11 . Detach cable from fixtures.

Fig 11: Detaching Cable Plug From Reverse Gear Switch

G00374670

Courtesy of BMW OF NORTH AMERICA, INC.

Detach retaining clip (1). See Fig 12 . Withdraw selector rod (2) from joint and remove washers (3). Upon installation: grease selector rod. Pay attention to installation position of washers (3).

Fig 12: Disconnecting Shift Rod

G00382244

Courtesy of BMW OF NORTH AMERICA, INC.

Lever out spring (1) with a screwdriver from lug (2) on housing. See Fig 13 . Tilt spring (1) upwards.

Fig 13: Levering Out Spring

G00374668

Courtesy of BMW OF NORTH AMERICA, INC.

Remove bearing pin (1). See Fig 14 . Upon installation: grease bearing pin (1).

Fig 14: Removing Bearing Pin

G00374669

Courtesy of BMW OF NORTH AMERICA, INC.

Support engine at front with a hydraulic lifter. See Fig 15 .

Fig 15: Supporting Engine At Front

G00367903

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Do not allow the transmission to hang off from the transmission input shaft as this will deform the clutch plate.

Release screws. See Fig 16 . Pull out transmission towards rear as far as possible, turn approx. 10° counterclockwise and remove. Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Fig 16: Locating Transmission Mounting Screws

G00374671

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: pay attention to adapter sleeves (1, 2), replace if necessary. See Fig 17 . Ensure correct position of cover plate.

Fig 17: Checking Dowel Sleeves

G00374647

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: remove release unit and release lever, clean and apply grease to relevant points.

Installation: Check lubrication of transmission input shaft for sticky consistency. See Fig 18 . If grease is sticky, replace clutch plate. Check clutch plate for friction rust in taper splines and replace if necessary. Mechanically remove old grease and lining abrasion from the taper splines of the clutch disk (with a cloth). Then apply a thin and even coat of grease with a brush in entire area of taper splines. Also in taper groove and on guide pin.

To complete installation, reverse removal procedure.

Fig 18: Checking Lubrication Of Transmission Input Shaft

G00374648

Courtesy of BMW OF NORTH AMERICA, INC.