Removing and installing the transmission (GS6X60DA/BA) (Cooper Clubman models with AWD)

Special tools required:

00 2 030
23 4 150

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 above will result in serious damage to the engine block and transmission.

Safety instructions:

Before removing the transmission, it is essential to check the firm fit of the engine mount and ensure that the rubber seals of the engine mount is in perfect condition. If the rubber seals are porous and has cracks, remove the TRANSMISSION WITH ENGINE .

Preliminary work needed:

Remove VEHICLE BATTERY .
Drain off TRANSMISSION OIL .
Secure engine in INSTALLATION POSITION .
Remove front AXLE SUPPORT .

No wheel alignment is required for removal and installation of front axle support.

Release transmission end OIL PAN screw connection.
Remove STARTER MOTOR .
Remove left OUTPUT SHAFT only at transmission end and hang up.
Remove right OUTPUT SHAFT only at transmission end and hang up.
Remove TRANSFER BOX .

Removal:

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Unscrew the screws (1).

Release vehicle battery partition wall (2) from holder and remove.

Release control unit (3) from holder.

Detach wiring harness (4) from battery tray (5). Remove battery tray (5).

Disengage the clip on the stop/holder (2), while doing so slightly bend away the lugs from the stop/holder (2).

Release screw (1) and release ground strap from transmission.

IMPORTANT: Do not tilt the selector lever cables in the stop/holder during removal.

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Lever the insert stands (3) of the selector lever cables from the ball joints with the open-end wrench SW13.

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Disconnect plug connection (2) of gear sensor.

Detach cable (1) with holder from transmission.

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NOTE: Pressure line of clutch slave cylinder remains connected.

IMPORTANT: Slowly relieve tension on clutch slave cylinder otherwise air may be drawn in through sealing sleeve.

If possible, do not deflect push rod of clutch slave cylinder.

A deflection of the push rod caused by removal will cause easy leakage of fluid. This leakage of fluid does not mean that the clutch slave cylinder is damaged.

Replacement is therefore not necessary!

Release screws (1) and remove clutch slave cylinder head.

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Unscrew the screws (1).

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Unscrew the screws (1).

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Supporting transmission:

With special tools 23 4 150 and 00 2 030

Support transmission from underneath.

Secure transmission with luggage strap (3).

Tasks are described in TRANSMISSION HOLDER .

Check the transmission oil level after having completed the repair.

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Loosen screws.

IMPORTANT: Do not allow transmission to hang on transmission input shaft when removing, as the clutch disc will be deformed.

Pull transmission downwards and remove.

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Check that lining sleeves (1) are correctly seated.

Replace damaged lining sleeves.

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Remove grease from transmission input shaft and clean shaft.

Do not grease transmission input shaft.

Check CLUTCH DISC for contact corrosion in gearing and replace if necessary.

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Installation:

NOTE:

If reusing the clutch:

Mechanically remove existing grease and lining abrasion from gearings of clutch disc (with a cloth).

Clean clutch hub and re-grease.

In new clutch discs the gearing is already greased.

Use BMW approved grease.

Remove and clean RELEASE BEARING AND RELEASE LEVER .

IMPORTANT: Before installation, check the threaded holes on the transmission for damage.

If the threaded holes are damaged, install HELICOIL insert M10x25 (part number 33 30 6 782 756).

IMPORTANT: Do not allow transmission to hang on transmission input shaft when installing, as the clutch disc will be deformed.

Failure to comply with this instruction above will result in serious damage to the transmission.

IMPORTANT: The use of screws of improper length can lead to component damage.

Note the exact screw length.

Install screws that correspond to the original length.

The oil pan can be damaged if the wrong screw length is used!

Incorrect : Do not use screw (1) (starter screw connection) for the lower screw connection of the transmission.

Correct : Use screw (2) (M8x40) under all circumstances for the lower screw connection of the transmission and flange-mount the transmission.

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Tighten screws (arrows).

Tightening torque 23 00 1AZ .

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Tighten down screws (1).

Tightening torque 22 32 1AZ .

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Tighten down screws (1).

Tightening torque 23 00 1AZ .

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Install clutch slave cylinder.

Tighten down screws (1).

Tightening torque 21 52 1AZ .

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Insert plug connection (2) of gear sensor.

Clamp cable (1) with holder on transmission.

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IMPORTANT: Check if the clip on the stop/holder (2) are undamaged.
Check if the insert stands on the ends of the selector lever cables (3) are undamaged.

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Tighten ground strap on transmission with screw (1).

Manually insert the clip on the stop/holder (2), without twisting the selector lever cable.

IMPORTANT: Make sure that the clips audibly lock. Afterwards, manually check for a firm fit.

Press the insert stands (3) of the selector lever cables onto the ball joints, without twisting the selector lever cables.

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Install battery tray (5).

Tighten down screws (1).

Install wiring harness (4) on battery tray (5).

Insert control unit (3) in holder.

Insert vehicle battery partition wall (2) in holder.

Required reworking:

Install TRANSFER BOX .
Replace right RADIAL SHAFT SEAL on differential.
Install left OUTPUT SHAFT .
Install right OUTPUT SHAFT .
Tighten transmission end OIL PAN screw connection.
Install STARTER .
Install front AXLE SUPPORT .

No wheel alignment is required for removal and installation of front axle support.

Add TRANSMISSION FLUID .
Install VEHICLE BATTERY .