28 00 001 Removing and installing twin clutch transmission (GS7D36SG) S65
Special tools required
After completion of work, check TRANSMISSION OIL LEVEL .
Use only the approved gear oil for dual clutch transmission.
Failure to comply with this instruction will result in serious damage to the twin clutch transmission.
Apply a thin coating of "MI - Setral-43N" grease to transmission input shaft!
Necessary preliminary tasks
- Read out transmission data of the gearbox to be replaced with the BMW diagnosis system
- Clamp off battery . See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY or DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD .
- Remove both left/ right suspension cross-brace. See 51 71 345 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION CROSSBRACE .
- Remove underbody protection . See 5147490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION or 5147491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION at front and rear.
- Remove REINFORCEMENT PLATE
- Remove COMPLETE EXHAUST SYSTEM
- Remove PROPELLER SHAFT
Release screw (1).
Unlock and disconnect plug (2).
Release cable (3) from holders.
Release screws (1).
Remove retaining plate (2).
Release screws (1).
Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .
Release screw (2).
Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .
Remove input speed sensor (3).
Release screw (1).
Unlock retainer (2).
Release cable from lever and holder.
Release screw (1).
Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .
Disconnect hydraulic lines (2) to transmission fluid cooler.
Close off hydraulic lines and connecting bores on thermostat with plugs.
Installation:
Replace sealing rings (1).
mount O-rings (1) onto line.
wet O-rings (1) and connecting bores with transmission oil DCTF-1.
do not install dry O-rings.
Supporting transmission
Support transmission with special tools 23 4 050 FIXTURE , 00 2 030 DEVICE .
Secure transmission to mounting with tensioning strap (1).
After completion of work, check transmission oil level.
Bolt special tool 11 9 990 DEVICE with bolt (1) to front axle support.
Bolt (2) is required to secure the engine in the correct position.
Adjust special tool 11 9 990 DEVICE until dimension A=50 mm is obtained between front axle support and tensioner.
Remove CROSSMEMBER FOR TRANSMISSION MOUNTING (S65) .
Release screw (1).
Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .
Remove transmission fluid thermostat (2).
Close off connecting bores on transmission and thermostat with plugs.
Installation:
Replace sealing rings.
Clean screw thread.
mount O-rings (1) onto line.
wet O-rings (1) and connecting bores with transmission oil DCTF-1.
do not install dry O-rings.
Screw (2) must be coated with Loctite 243 prior to installation.
- Unlock and disconnect plug (1) by turning.
- Do not touch pins.
- Release cable from retainers.
- Insert special tool 24-2390 CAP in sealing sleeve.
Operations are described in:
Installation:
Pay attention to routing and length of wiring harness.
Insert special tool 24-2390 CAP in sealing sleeve (1).
Release screws (1).
Tightening torque, see 28 10 HOUSING WITH ADD-ON PARTS .
Pull oil - coolant heat exchanger towards rear out of guide (2).
Installation:
Oil-coolant heat exchanger and transmission oil thermostat remain on vehicle during removal of transmission.
Release wiring harness.
Installation:
- Connection (1), monitoring sensor, left: shortened corrugated tubing (wiring visible between end of corrugated tubing and plug housing).
- Connection (2), monitoring sensor, right: cable lug with designation "R", corrugated tubing closed off at plug housing (wiring not visible).
Release screws (1) and (2).
Tightening torque, see 28 00 DOUBLE CLUTCH GEARBOX .
Bolt (3) is for securing the starter.
Installation:
Apply a thin coating of "MI-Setral-43N" grease to transmission input shaft.
BMW part number EU: 83 23 2 152 082
BMW part number USA: 83 23 2 152 081