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    BMW 318/325/M3/525/535/M5 1989-1993 Repair Information

    Transmission

    Print

    REMOVAL & INSTALLATION



    E30 3 Series
    1. Disconnect the negative battery cable. Raise and safely support the vehicle. Remove the exhaust system. Remove the cross brace and heat shield. On the 325iX, remove the transfer case.
    2.  
    3. Hold the nuts on the front with one wrench, and remove bolts from the rear with another to disconnect the flexible coupling at the front of the driveshaft. Some vehicles have a vibration damper at this point in the drivetrain. This damper is mounted on the transmission output flange with bolts that are pressed into the damper. On these vehicles, unscrew and remove the nuts located behind the damper.
    4.  
    5. Loosen the threaded sleeve on the driveshaft. Get a special tool to hold the splined portion of the shaft while turning the sleeve.
    6.  
    7. Remove its mounting bolts and remove the center driveshaft mount. Then, bend the driveshaft down at the center and pull it off the transmission output flange. Keep the sections of the driveshaft from pulling apart and suspend it from the vehicle with wire.
    8.  
    9. Remove the retainer and washer, and pull out the shift selector rod.
    10.  
    11. Use a hex-head wrench to remove the self-locking bolts that retain the shift rod bracket at the rear of the transmission and then remove the bracket. If the vehicle has a shift arm, use a screwdriver to pry the spring clip up off the boss on the transmission case and swing it upward. Then, pull out the shift shaft pin.
    12.  
    13. Unscrew and remove the clutch slave cylinder and support it so the hydraulic line can remain connected.
    14.  
    15. The transmission may incorporate sending units for flywheel rotating speed and position. Remove the heat shield that protects these from exhaust heat and then remove the retaining bolt for each sending unit. Note that the speed sending unit, which has no identifying ring goes in the bore on the right, and that the reference mark sending unit, which has a marking ring, goes in the bore on the left. If the sending units are installed in reverse positions, the engine will not run at all. Pull these units out of the flywheel housing.
    16.  
    17. Disconnect the wiring connector going to the backup light switch and pull the wires out of the harness.
    18.  
    19. Support the transmission from underneath in a secure manner. Remove mounting bolts and remove the crossmember holding the rear of the transmission to the body. Then, lower the transmission onto the front axle carrier.
    20.  
    21. Using the proper tool, remove the bolts holding the transmission flywheel housing to the engine at the front. If there is a separate clutch bellhousing, remove the transmission to bellhousing bolts. Make sure to retain the washers with the bolts. Pull the transmission rearward to slide the input shaft out of the clutch disc and then lower the transmission and remove from the vehicle.
    22.  

    To install:
    1. Install the transmission in position under the vehicle. Align the input shaft and install the transmission, note the following points:
    2.  

    1. Coat the input shaft splines and flywheel housing guide pins with a light coating of suitable grease. Coat the release bearing interior groove with grease.
    2.  
    3. Make sure the front mounting bolts are installed with their washers. For hex head bolts, torque the M8 bolts to 16-19.5 ft. lbs. (22-27 Nm), torque the M10 bolts to 34-37 ft. lbs. (47-51 Nm), torque the M12 bolts to 48-59 ft. lbs. (66-82 Nm). For Torx® head bolts, torque the M8 bolts to 14.5-17 ft. lbs. (20-24 Nm), torque the M10 bolts to 27.5-34 ft. lbs. (38-47 Nm), torque the M12 bolts to 52-58 ft. lbs. (70-80 Nm).
    4.  
    5. Before reinstalling the sending units for flywheel position and speed, make sure their faces are free of either grease or dirt and then coat them with a light coating of a suitable lubricant. Inspect the O-rings and replace them if they are cut, cracked, crushed, or stretched.
    6.  
    7. When installing the shift rod bracket at the rear of the transmission, use new self-locking bolts and make sure the bracket is level before tightening them. Torque the shift rod bracket bolts to 16.5 ft. lbs. (22 Nm) except with the S14 engine, which uses an aluminum bracket. With the S14 engine, torque these bolts to 8 ft. lbs. (12 Nm).
    8.  
    9. Install the clutch slave cylinder.
    10.  
    11. When installing the driveshaft center bearing, preload it forward 0.157-0.236 inch Check the driveshaft alignment with an appropriate tool such. Replace the nuts and then torque the center mount bolts to 16-17 ft. lbs. (21-23 Nm).
    12.  
    13. Torque the M10-8.8 flexible coupling bolts to 35 ft. lbs. (48 Nm). Torque the M10-10.9 flexible coupling bolts to 52 ft. lbs. (72 Nm).
    14.  
    15. Torque the driveshaft threaded sleeve to 12 ft. lbs. (17 Nm) after it complete installation.
    16.  
    17. Fill the transmission with proper lubricant.
    18.  

    E36 3 Series
    1. Disconnect the negative battery cable. Raise and safely support the vehicle. Remove the exhaust system. Remove the cross brace and heat shield.
    2.  
    3. Hold the nuts on the front with one wrench, and remove bolts from the rear with another to disconnect the flexible coupling at the front of the driveshaft. Some vehicles have a vibration damper at this point in the drivetrain. This damper is mounted on the transmission output flange with bolts that are pressed into the damper. On these vehicles, unscrew and remove the nuts located behind the damper.
    4.  
    5. Loosen the threaded sleeve on the driveshaft. Get a special tool to hold the splined portion of the shaft while turning the sleeve.
    6.  
    7. Remove its mounting bolts and remove the center driveshaft mount. Then, bend the driveshaft down at the center and pull it off the transmission output flange. Keep the sections of the driveshaft from pulling apart and suspend it from the vehicle with wire.
    8.  
    9. Remove the retainer and washer, and pull out the shift selector rod.
    10.  
    11. Unscrew and remove the clutch slave cylinder and support it so the hydraulic line can remain connected.
    12.  
    13. Disconnect the wiring connector going to the backup light switch and pull the wires out of the harness.
    14.  
    15. Support the rear of the engine to prevent it from falling down at the rear.
    16.  
    17. Support the transmission from underneath in a secure manner. Remove mounting bolts and remove the crossmember holding the rear of the transmission to the body. Then, lower the transmission onto the front axle carrier.
    18.  
    19. Use a screwdriver to pry the shift arm spring clip up off the boss on the transmission case and swing it upward. Then, pull out the shift shaft pin.
    20.  
    21. Using the proper tool, remove the bolts holding the transmission flywheel housing to the engine at the front. If there is a separate clutch bellhousing, remove the transmission to bellhousing bolts. Make sure to retain the washers with the bolts. Pull the transmission rearward to slide the input shaft out of the clutch disc and then lower the transmission and remove from the vehicle.
    22.  

    To install:
    1. Install the transmission in position under the vehicle. Align the input shaft and install the transmission, note the following points:
    2.  

    1. Coat the input shaft splines and flywheel housing guide pins with a light coating of suitable grease. Coat the release bearing interior groove with grease.
    2.  
    3. Make sure the front mounting bolts are installed with their washers. For hex head bolts, torque the M8 bolts to 16-19.5 ft. lbs. (22-27 Nm), torque the M10 bolts to 34-37 ft. lbs. (47-51 Nm), torque the M12 bolts to 48-59 ft. lbs. (66-82 Nm). For Torx® head bolts, torque the M8 bolts to 14.5-17 ft. lbs. (20-24 Nm), torque the M10 bolts to 27.5-34 ft. lbs. (38-47 Nm), torque the M12 bolts to 52-58 ft. lbs. (70-80 Nm).
    4.  
    5. Replace the shift arm and press the spring clip into place.
    6.  
    7. Install the clutch slave cylinder.
    8.  
    9. When installing the driveshaft center bearing, preload it forward 0.157-0.236 inch Check the driveshaft alignment with an appropriate tool such. Replace the nuts and then torque the center mount bolts to 16-17 ft. lbs. (21-23 Nm).
    10.  
    11. Torque the M10-8.8 flexible coupling bolts to 35 ft. lbs. (48 Nm). Torque the M10-10.9 flexible coupling bolts to 52 ft. lbs. (72 Nm).
    12.  
    13. Torque the driveshaft threaded sleeve to 12 ft. lbs. (17 Nm) after it complete installation.
    14.  
    15. Fill the transmission with proper lubricant.
    16.  

    E34 5 Series
    1. Disconnect the negative battery cable. Raise and safely support the vehicle. Remove the exhaust system. Remove the attaching bolts and remove the heat shield mounted just to the rear of the transmission on the floorpan.
    2.  
    3. Support the transmission securely from underneath. Then, remove the crossmember that supports it at the rear from the body by removing the mounting bolts on both sides.
    4.  
    5. Using wrenches on both the bolt heads and on the nuts, remove the bolts passing through the vibration damper and front universal joint at the front of the driveshaft.
    6.  
    7. Remove its mounting bolts and remove the center driveshaft mount. Then, bend the driveshaft down at the center and pull it off the transmission output flange. Keep the sections of the driveshaft from pulling apart and suspend it from the vehicle with wire.
    8.  
    9. Pull out the circlip, slide off the washer, and then pull the shift selector rod off the transmission shift shaft. Disconnect the backup light switch.
    10.  
    11. Lower the transmission slightly for access. Then, use a small prybar to lift the spring out of the holder on the bracket and then raise the arm. Pull out the shift shaft bolt.
    12.  
    13. Remove the upper and lower attaching nuts and remove the clutch slave cylinder, supporting it so the hydraulic line need not be disconnected.
    14.  
    15. Unscrew the bolts fastening the transmission to the bell housing. Use a Torx® wrench to remove the bolts. Make sure to retain the washer with each bolt to ensure that they can be readily removed later, if necessary. Pull the transmission rearward until the input shaft has disengaged from the clutch disc and then lower and remove the transmission.
    16.  

    To install:
    1. Install the transmission in position under the vehicle. Align the input shaft and install the transmission. Follow these procedures:
    2.  

    1. Coat the input shaft splines and flywheel housing guide pins with a light coating of suitable grease. Coat the release bearing interior groove with grease.
    2.  
    3. Make sure the front mounting bolts are installed with their washers. For hex head bolts, torque the M8 bolts to 16-19.5 ft. lbs. (22-27 Nm), torque the M10 bolts to 34-37 ft. lbs. (47-51 Nm), torque the M12 bolts to 48-59 ft. lbs. (66-82 Nm). For Torx® head bolts, torque the M8 bolts to 14.5-17 ft. lbs. (20-24 Nm), torque the M10 bolts to 27.5-34 ft. lbs. (38-47 Nm), torque the M12 bolts to 52-58 ft. lbs. (70-80 Nm).
    4.  
    5. Replace the shift arm and press the spring clip into place.
    6.  
    7. Install the clutch slave cylinder.
    8.  
    9. When installing the driveshaft center bearing, preload it forward 0.157-0.236 inch Check the driveshaft alignment with an appropriate tool such. Replace the nuts and then torque the center mount bolts to 16-17 ft. lbs. (21-23 Nm).
    10.  
    11. Torque the M10-8.8 flexible coupling bolts to 35 ft. lbs. (48 Nm). Torque the M10-10.9 flexible coupling bolts to 52 ft. lbs. (72 Nm).
    12.  
    13. Torque the driveshaft threaded sleeve to 12 ft. lbs. (17 Nm) after it complete installation.
    14.  
    15. Fill the transmission with proper lubricant.
    16.  

    260 Series Transmissions

    See Figures 1, 2 and 3



    Click image to see an enlarged view

    Fig. Fig. 1: Getrag 260 transmission



    Click image to see an enlarged view

    Fig. Fig. 2: Shift components of Getrag 260 transmission



    Click image to see an enlarged view

    Fig. Fig. 3: Gear set of Getrag 260 transmission

    1. Remove the drain plug and drain the fluid from the transmission. Remove the transmission.
    2.  
    3. Disconnect the spring and remove the release bearing and arm.
    4.  
    5. Remove the bolts holding the release bearing sleeve to the transmission case. Save the shims for replacement.
    6.  
    7. Remove the reverse light switch from the side of the transmission. Remove the plug located forward of the reverse light switch and pull out the lockpin and spring. Note the position of the lockpin when removing.
    8.  
    9. Remove the snapring and washer from around the input shaft. Remove the bolt from the left side of the transmission case at the rear.
    10.  
    11. Drive out the pins from the rear housing joint. Remove the bolts noting the locations. The top, right bolt is 8x60mm.
    12.  
    13. Pull the front case off the transmission using tool 23 1 460 and 33 1 301 or equivalent. Do not hammer on the sides of the case to remove. The tools mount a plate to the release bearing sleeve threaded holes and use a slide hammer to evenly tap the front case off the rear housing.
    14.  

    To install:
    1. Place the roller bearing on the lay shaft with the small end facing out. Coat the rollers with grease to facilitate assembly.
    2.  
    3. Clean the area in the front case where the reverse gear shaft mounts. Coat the area with sealing compound.
    4.  
    5. Remove the input shaft bearing. Clean the mating faces and coat with a sealing compound.
    6.  
    7. Except with M30 engine, place the front case over the transmission. Align the intermediate shaft with the bearing race using the drain plug hole for access. Press on the input shaft bearing with the protruding inner race side towards the gearset.
    8.  
    9. With M30 engine, install the input shaft bearing in the front case with the protruding side of the inner race towards the gearset. Heat the inner bearing race with a heat gun to 175°F. (80°C.), being careful of the plastic bearing cage. Slide the front case over the input shaft, aligning the intermediate shaft in the bearing race.
    10.  
    11. Torque the case mounting bolts to 16 ft. lbs. (22 Nm). Install the lock pin, spring and plug. Install the reverse light switch. Install the dowel pin in the case. Install the bolt in the side of the transmission case.
    12.  
    13. Install the shim(s) between the input shaft snapring and the bearing. Install the shims so the play is 0.0000-0.0035 inch (0.00-0.09mm).
    14.  
    15. Install the release bearing sleeve with the oil groove mounted in line with the oil bore in the transmission case. Measure the distance from the outer bearing race to the flange on the sleeve and adjust the play with shims to 0.0000-0.0035 inch (0.00-0.09mm). Torque the M6 bolts to 7 ft. lbs. (10 Nm), the M8x22 bolts to 13 ft. lbs. (18 Nm) and the M8x30 bolts to 18 ft. lbs. (25 Nm).
    16.  
    17. Fill the groove inside the release bearing with moly grease, except with the dual mass flywheel which uses Microlube® 261 or equivalent. Apply the same grease to the release arm pivot points. Install the release shaft and bearing.
    18.  

    240 Series Transmissions

    See Figures 4 and 5



    Click image to see an enlarged view

    Fig. Fig. 4: Getrag 260 transmission



    Click image to see an enlarged view

    Fig. Fig. 5: Shift components of Getrag 240 transmission

    1. Remove the drain plug and drain the fluid from the transmission. Remove the transmission.
    2.  
    3. Disconnect the spring and remove the release bearing and arm.
    4.  
    5. Remove the bolts holding the release bearing sleeve to the transmission case. Save the shims for replacement.
    6.  
    7. Remove the plug and pull out the lockpin and spring. Note the position of the lockpin when removing.
    8.  
    9. Remove the snapring and washer from around the input shaft. Use a bearing puller and pull the input shaft bearing from the case.
    10.  
    11. Drive out the pins from the rear housing joint. Remove the bolts noting the locations.
    12.  
    13. Pull the front case off the transmission. Do not hammer on the sides of the case to remove.
    14.  

    To install:
    1. Clean the mating faces and coat with a sealing compound. Place the front case over the transmission. Heat the inner bearing race with a heat gun to 175°F. (80°C.), being careful of the plastic bearing cage. Press on the input shaft bearing until it seats.
    2.  
    3. Torque the case mounting bolts to 16 ft. lbs. (22 Nm). Install the lock pin, spring and plug. Install the dowel pin in the case.
    4.  
    5. Install the release bearing sleeve with the oil groove mounted in line with the oil bore in the transmission case. Measure the distance from the outer bearing race to the flange on the sleeve and adjust the play with shims to 0.0000-0.0035 inch (0.00-0.09mm). Torque the M6 bolts to 7 ft. lbs. (10 Nm), the M8x22 bolts to 13 ft. lbs. (18 Nm) and the M8x30 bolts to 18 ft. lbs. (25 Nm). Use sealer on the flange.
    6.  
    7. Fill the groove inside the release bearing with moly grease, except with the dual mass flywheel which uses Microlube® 261 or equivalent. Apply the same grease to the release arm pivot points. Install the release shaft and bearing.
    8.  

    265 Series Transmissions
    1. Remove the drain plug and drain the fluid from the transmission. Remove the transmission.
    2.  
    3. Disconnect the spring and remove the release bearing and arm.
    4.  
    5. Remove the bolts holding the release bearing sleeve to the transmission case. Save the shims for replacement.
    6.  
    7. Remove the snapring and washer from around the input shaft. Remove the bolts from the cover under the input shaft. Pry out the cover and remove the shim. Engage 4th gear and hold the output flange. Remove the bolt from under the cover.
    8.  
    9. Remove the reverse light switch. Remove the plug and pull out the lockpin and spring. Note the position of the lockpin when removing.
    10.  
    11. Drive out the pins from the rear housing joint. Remove the bolts noting the locations.
    12.  
    13. Pull the front case off the transmission. Do not hammer on the sides of the case to remove.
    14.  

    To install:
    1. Clean the mating faces and coat with a sealing compound. Place the front case over the transmission. Heat the inner bearing race with a heat gun to 175°F. (80°C.), being careful of the plastic bearing cage. Draw up the input shaft to seat the bearing.
    2.  
    3. Torque the case mounting bolts to 16 ft. lbs. (22 Nm). Install the lock pin, spring and plug. Install the dowel pin in the case. Install the reverse light switch.
    4.  
    5. Install the release bearing sleeve with the oil groove mounted in line with the oil bore in the transmission case. Measure the distance from the outer bearing race to the flange on the sleeve and adjust the play with shims to 0.0000-0.0035 inch (0.00-0.09mm). Torque the M6 bolts to 7 ft. lbs. (10 Nm), the M8x22 bolts to 13 ft. lbs. (18 Nm) and the M8x30 bolts to 18 ft. lbs. (25 Nm). Use sealer on the flange
    6.  
    7. Fill the groove inside the release bearing with moly grease, except with the dual mass flywheel which uses Microlube® 261 or equivalent. Apply the same grease to the release arm pivot points. Install the release shaft and bearing.
    8.  

    280 Series Transmissions
    1. Remove the drain plug and drain the fluid from the transmission. Remove the transmission.
    2.  
    3. Disconnect the spring and remove the release bearing and arm.
    4.  
    5. Remove the bolts holding the release bearing sleeve to the transmission case. Save the shims for replacement.
    6.  
    7. Remove the snapring and washer from around the input shaft. Remove the bolts from the cover under the input shaft. Pry out the cover and remove the shim. Engage 4th gear and hold the output flange. Remove the bolt from under the cover.
    8.  
    9. Remove the reverse light switch. Remove the plug and pull out the lockpin and spring. Note the position of the lockpin when removing.
    10.  
    11. Drive out the pins from the rear housing joint. Remove the bolts noting the locations.
    12.  
    13. Pull the front case off the transmission. Do not hammer on the sides of the case to remove.
    14.  

    To install:
    1. Clean the mating faces and coat with a sealing compound. Place the front case over the transmission. Heat the inner bearing race with a heat gun to 175°F. (80°C.), being careful of the plastic bearing cage. Draw up the input shaft to seat the bearing.
    2.  
    3. Torque the case mounting bolts to 16 ft. lbs. (22 Nm). Install the lock pin, spring and plug. Install the dowel pin in the case. Install the reverse light switch.
    4.  
    5. Install the bolt in the end of the shaft with thread sealer. Install the shim and sealing cover.
    6.  
    7. Install the release bearing sleeve with the oil groove mounted in line with the oil bore in the transmission case. Measure the distance from the outer bearing race to the flange on the sleeve and adjust the play with shims to 0.0000-0.0035 inch (0.00-0.09mm). Torque the M6 bolts to 7 ft. lbs. (10 Nm), the M8x22 bolts to 13 ft. lbs. (18 Nm) and the M8x30 bolts to 18 ft. lbs. (25 Nm). Use sealer on the flange.
    8.  
    9. Fill the groove inside the release bearing with moly grease, except with the dual mass flywheel which uses Microlube® 261 or equivalent. Apply the same grease to the release arm pivot points. Install the release shaft and bearing.
    10.  

    S5D 200G/250G Series Transmissions
    1. Remove the drain plug and drain the fluid from the transmission. Remove the transmission.
    2.  
    3. Disconnect the spring and remove the release bearing and arm
    4.  
    5. Remove the locking plate from the output flange. Hold the flange and remove the nut. Pull the flange off the output shaft. Remove the seal from the bore.
    6.  
    7. Remove the 2 bolts holding the cover at the rear top of the transmission. Remove the springs and balls from the bores. A magnet may be needed to remove the balls. Place a lock pin in the center hole with the transmission in 2nd gear.
    8.  
    9. Remove the 4 bolts from the cover under the output shaft. Take note of the insulators under the bolt heads.
    10.  
    11. Remove the reverse light switch, the bolt above the switch and the cover to the right of the switch. The cover will need to be pried out. Remove the spring and pin. Note the position of the pin for installation.
    12.  
    13. Remove the reverse gear shaft bolts located on the slave cylinder side of the transmission.
    14.  
    15. Loosen the case mounting bolts and press out the dowel pins. Pull off the rear transmission housing.
    16.  

    To install
    1. Clean the mating surfaces of the cases and slide the case together. Install bolts and new seals to the cover under the output shaft. Drive in the dowel pins. Install the case bolts and torque to 16 ft. lbs. (22 Nm).
    2.  
    3. Install the reverse gear shaft bolts with threadlocker. Install new seals for the shifter rod and the output shaft. Install the output flange and nut. Torque to 123 ft. lbs. (170 Nm), loosen, then torque to 87 ft. lbs. (120 Nm). Install the lock plate.
    4.  
    5. Install the Locking balls and the springs. Install the springs and dowels. Install the cover plate with the bolts and threadlocker.
    6.  
    7. Install the catch pin with the roller horizontal. Install the spring and end cap.
    8.  
    9. Install the reverse light switch and the bolt. Use threadlocker on the bolt.
    10.  

    S5D 310Z Series Transmissions
    1. Remove the drain plug and drain the fluid from the transmission. Remove the transmission.
    2.  
    3. Disconnect the spring and remove the release bearing and arm.
    4.  
    5. Remove the release bearing sleeve. Remove the seal by punching holes where the indentations are and driving one side in while using a screw to press out the other side. Pull the seal out by the screw.
    6.  
    7. Slide tool 23 2 380 or equivalent over the input shaft. This tool is a sleeve that fits over the input shaft. It allows the removal of the input shaft snapring over the input shaft without scratching the coating on the input shaft. Remove the snapring and place it on the tool sleeve. Remove the sleeve. Remove the spacer.
    8.  
    9. Remove the bolts on the front portion of the transmission case in the area of the slave cylinder.
    10.  
    11. Remove the reverse light switch and the bolt above it.
    12.  
    13. Remove the snapring from the forward most bore on the right side of the transmission case. Remove the cover, spring and catch pin.
    14.  
    15. Remove the case bolts and pull off the transmission case. Do not use a hammer to separate the halves.
    16.  

    1. Use a piece of string to hold the 5th/reverse gear shift arm in the horizontal position. Slide the case on to the dowel pins. Use 2 bolts to center the case. Use too 23 2 293 and 23 2 290 or equivalent, to draw the case together only enough so the string can still be removed.
    2.  
    3. Install the 5th/reverse gear shift arm bolt hand tight. Remove the string and draw the case together. Install the case bolts and torque to 16 ft. lbs. (22 Nm).
    4.  
    5. Install the side bolts with sealer and tighten.
    6.  
    7. Install the catch pin, spring, cover and snapring. Install the reverse light switch.
    8.  
    9. Install the input shaft spacer and snapring. Use the shaft protection tool used in the removal of the snapring. Install a new seal lubricated with ATF. Install the release bearing sleeve and torque the M6 bolts to 7 ft. lbs. (10 Nm), the M8x22 bolts to 13 ft. lbs. (18 Nm) and the M8x30 bolts to 18 ft. lbs. (25 Nm).
    10.  

     
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