28 00 001 Removing and installing twin-clutch gearbox (GS7D36SG) S63

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Special tools required:

IMPORTANT: To prevent heavy damage to the engine block, the protruding thread of the transmission bolts absolutely must be checked for damage and corrosion before removal .
If there are signs of corrosion, the rust must be removed and the threads must be cleaned before removal .
Replace rusted, damaged screws.

Failure to comply with this instruction will result in serious damage to the engine block and transmission.

IMPORTANT: Before the gearbox is removed, it is imperative that a readout is taken of the specific gearbox data status using ISTA/P .
Twin-clutch gearbox must be shifted to position "N" before removal.
Changing gears is only possible with engine running!
After completion of repair work, CHECK TRANSMISSION OIL LEVEL .
Use only the approved TRANSMISSION OIL .

Failure to comply with this requirement will result in serious damage to the twin-clutch gearbox!

Apply a thin coating of "MI-Setral-43N" grease to transmission input shaft.

Necessary preliminary tasks:

Read out the gearbox data status via ISTA/P for the gearbox to be replaced.
Shift transmission to position "N".
Disconnect the BATTERY
Remove ENGINE ACOUSTIC COVER
Remove underbody protection . See 51 47 491 REMOVING REFITTING/REPLACING REAR ENGINE UNDERCOVER or 51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION at front and rear
Remove complete EXHAUST SYSTEM
Remove PROPELLER SHAFT
Support engine with jack when removing gearbox

Release screws (1).

Tightening torque 28 00 1AZ.

	Type	Thread	Tightening Specifications	Dimension
Steel Torx Screw	GS7D36SG	M8x50		19 Nm
	GS7D36SG	M10		38 Nm
	GS7D36SG	M12		66 Nm
Aluminum screws/bolts are not magnetic N54/N55	GS7D36SG		Replace screws Jointing torque and angle of rotation must be observed without fail
Aluminum screws/bolts are not magnetic N54/N55	GS7D36SG	M12	Jointing torque Angle of rotation	25 Nm 130 °
Aluminum screws/bolts are not magnetic S55	GS7D36SG	M8	Jointing torque Angle of rotation	8 Nm 90 °

Installation note:

Make sure the acoustic insert (2) is fitted correctly when removing and installing the transmission.

When installing the transmission, the acoustic insert (2) must be installed.

Fig 1: Identifying Screws And Acoustic Insert

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Detach cable clip (1) from gearbox.

Release screw (2).

Remove pulse sensor for crankshaft sensor (3).

Disconnect connector (4).

Tightening torque 13 62 4AZ .

Fig 2: Identifying Cable Clip, Connector And Screw

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Remove heat shield (1) on left and right of transmission.

Fig 3: Identifying Heat Shield

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Release screw (1).

Release holder (2) with hydraulic lines from transmission.

Fig 4: Identifying Holder And Screw

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Release screw (1).

Disconnect hydraulic lines (2) to transmission oil cooler.

Seal off pipes and connection holes on gearbox with plugs.

Installation note:

Replace sealing rings.

Fig 5: Identifying Hydraulic Lines And Screw

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Release screw (1).

Unlock retainer (2).

Release cable from lever and holder.

Fig 6: Identifying Screw And Retainer

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Supporting transmission:

Support transmission with special tools 23 4 050 , 00 2 030 .

Secure transmission to mounting with tensioning strap (1).

Tasks are described in GEARBOX HOLDER .

Fig 7: Supporting Transmission Using Special Tools 23 4 050

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Slacken nut (1).

Release grounding cable (2).

Release screws (3).

Tightening torque 22 32 3AZ .

Fig 8: Identifying Grounding Cable And Slacken Nut

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Release wiring harness (1) from bracket (2).

Unscrew nuts (3).

Tightening torque: 8 Nm

Remove panel (4).

Fig 9: Identifying Wiring Harness, Panel And Nuts

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Lower transmission
Unlock central transmission plug (1) by turning and disconnect.
Do not touch pins.
Release cable from brackets.

Operations are described in NOTES ON MECHATRONICS

IMPORTANT: Read and comply with important note.

Installation note:

Pay attention to the routing and length of the wiring harness.

Fig 10: Removing Central Transmission Plug

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Insert special tool 24 2 390 in sealing cup (1).

Fig 11: Inserting Special Tool 24 2 390 In Sealing Cup

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Release screws (1).

Unflange transmission.

Tightening torque (28 00 1AZ), see chart:

	Type	Thread	Tightening specifications	Dimension
Steel Torx screw	GS7D36SG	M8x50		19 Nm
	GS7D36SG	M10		38 Nm
	GS7D36SG	M12		66 Nm
Aluminum screws/bolts are not magnetic N54/N55	GS7D36SG		Replace screws Jointing torque and angle of rotation must be observed without fail
Aluminum screws/bolts are not magnetic N54/N55	GS7D36SG	M12	Jointing torque: Angle of rotation:	25 Nm 130 °
Aluminum screws/bolts are not magnetic S55	GS7D36SG	M8	Jointing torque: Angle of rotation:	8 Nm 90 °

Fig 12: Identifying Transmission Screws

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Installation note:

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

Check that fitting sleeves are correctly fitted.

Replace damaged fitting sleeves.

Fig 13: Identifying Sleeves

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Installation note:

Observe screw fastening sequence without fail.

Tightening torque, steel screws (28 00 1AZ), see chart:

	Type	Thread	Dimension
Steel Torx screw	GS7D36SG	M8x50	19 Nm
	GS7D36SG	M10	38 Nm
	GS7D36SG	M12	66 Nm

Fig 14: Transmission Housing Bolts Tightening/Loosening Sequence

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