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

Transmission

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REMOVAL & INSTALLATION



E30 3 Series

To perform this operation, a support for the transmission, BMW tool 24 0 120 and 00 2 020 or equivalent and a tool for tightening the driveshaft locking ring, BMW tool 26 1 040 or equivalent, are required.

  1. Disconnect the battery ground cable. Loosen the throttle cable adjusting nuts, release the cable tension, and disconnect the cable at the throttle lever. Then, remove (and retain) the nuts, and pull the cable housing out of the bracket.
  2.  
  3. Disconnect the exhaust system at the manifold and hangers and lower it aside. Remove the hanger that runs across under the driveshaft. Remove the exhaust heat shield from under the center of the vehicle.
  4.  
  5. On the 325iX, remove the transfer case from the rear of the transmission.
  6.  
  7. Drain the transmission oil and discard it. Remove the oil filler neck. Disconnect the oil cooler lines at the transmission by unscrewing the flare nuts and plug the open connections.
  8.  
  9. Support the transmission with the proper tools. Separate the torque converter housing from the transmission by removing the Torx® bolts with the proper tool from behind and the regular bolts from underneath. Retain the washers used with the Torx® bolts.
  10.  
  11. On the 325iX, disconnect the front driveshaft.
  12.  
  13. Remove bolts attaching the torque converter housing to the engine, making sure to retain the spacer used behind one of the bolts. Then, loosen the mounting bolts for the oil level switch just enough so the plate can be removed while pushing the switch mounting bracket to one side.
  14.  
  15. Remove the bolts attaching the torque converter to the drive plate. Turn the flywheel as necessary to gain access to each of the bolts, which are spaced at equal intervals around it. Make sure to re-use the same bolts and retain the washers.
  16.  
  17. To remove the speed and reference mark sensors, remove the attaching bolt for each and remove each sensor. Keep the sensors clean.
  18.  
  19. Turn the bayonet type electrical connector counterclockwise and then pull the plug out of the socket. Then, lift the wiring harness out of the harness bails.
  20.  
  21. Support the transmission using the proper jack. Then, remove the crossmember that supports the transmission at the rear.
  22.  
  23. Disconnect the transmission shift rod. Then, remove the nuts and then the through bolts from the damper-type U-joint at the front of the transmission.
  24.  
  25. Unscrew the driveshaft spline locking ring at the center mount, if equipped, using the special tool designed for this purpose. Then, remove the bolts and remove the center mount. Bend the driveshaft downward and pull it off the centering pin. Suspend it with wire from the underside of the vehicle.
  26.  
  27. Lower the transmission as far as possible. Then, remove all the Torx® or standard type bolts attaching the transmission to the engine.
  28.  
  29. Remove the small grill from the bottom of the transmission. Then press the converter off with a large prybar passing through this opening while sliding the transmission out.
  30.  

To install:
  1. Install the transmission in position under the vehicle and raise it into position. Observe the following points:
    1. Make sure the converter is fully installed onto the transmission-so the ring on the front is inside the edge of the case. Only use M10x16mm bolts as originally equipped or damage will occur.
    2.  
    3. When reinstalling the driveshaft, tighten the lockring with the proper tool.
    4.  
    5. Make sure to replace the self-locking nuts on the driveshaft flexible joint and to hold the bolts still while tightening the nuts to keep from distorting it.
    6.  
    7. When installing the center mount, preload it forward from its most natural position 0.157-0.236 inches.
    8.  
    9. When reconnecting the bayonet type electrical connector, make sure the alignment marks are aligned after the plug it twisted into its final position.
    10.  
    11. When reinstalling the speed and reference mark sensors, inspect the O-rings used on the sensors and install new ones, if necessary. Make sure to install the speed sensor into the bore marked D and the reference mark sensor, which is marked with a ring, into the bore marked B.
    12.  
    13. Torque the crossmember mounting bolts to 16-17 ft. lbs. (21-23 Nm).
    14.  
    15. If O-rings are used with the transmission oil cooler connections, replace them.
    16.  
    17. Adjust the throttle cables.
    18.  

  2.  

E36 3 Series
  1. Disconnect the negative battery terminal. Drain the transmission fluid and discard. Do not reuse the old oil. Remove the exhaust system.
  2.  
  3. Mark the mounted position of the crossmember under the driveshaft, the remove.
  4.  
  5. Disconnect the driveshaft from the output flange of the transmission. Loosen the driveshaft spline lockring and remove the center support from the floorpan. Position the driveshaft out of the way and support with wire.
  6.  
  7. Disconnect the shifter cable from the transmission and bracket. Disconnect the connectors from the transmission and the speed sender.
  8.  
  9. Pull out the access plug from the side of the case to reach the torque converter mounting bolts. Use tool 24 1 110 or equivalent to remove the bolts.
  10.  
  11. Place a transmission jack under the transmission and support. Disconnect the oxygen sensor cable and remove the transmission crossmember. Disconnect the oil cooler lines and clamps.
  12.  
  13. Remove the bolts from the transmission to engine joint. Pull the transmission back with the torque converter and lower.
  14.  

To install:
  1. Check the condition of the dowel sleeves and flexplate.
  2.  
  3. Align the torque converter and the flexplate. Place the transmission into position and bolt to the engine. With hexhead bolts, torque the M8 bolts to 17 ft. lbs. (24 Nm), the M10 bolts to 33 ft. lbs. (45 Nm) and the M12 bolts to 57-62 ft. lbs. (78-86 Nm). With Torx® bolts, torque the M8 bolts to 15 ft. lbs. (21 Nm), the M12 bolts to 52 ft. lbs. (72 Nm).
  4.  
  5. Torque the M10x16mm toque converter bolts to 33 ft. lbs. (45 Nm) with tool 24 1 110 or equivalent.
  6.  
  7. Install the oil cooler lines after checking the condition of the O-rings. Install the crossmember and wiring connections.
  8.  
  9. Connect the shifter cable and adjust. Install the driveshaft. Preload the center bearing 0.157-0.236 in (4-6 mm) forward. Torque the flange bolts to 59 ft. lbs. (81 Nm). After completing the installation, torque the spline locking ring to 12 ft. lbs. (17 Nm).
  10.  
  11. Install the crossmember over the driveshaft in the original mounting position. Install the exhaust system and splashguards. Fill the transmission and check the level. Connect the negative battery terminal.
  12.  

E34 5 Series
4HP 22
  1. Disconnect the battery ground cable. Loosen the throttle cable adjusting nuts, release the cable tension, and disconnect the cable at the throttle lever. Then, remove (and retain) the nuts, and pull the cable housing out of the bracket.
  2.  
  3. Disconnect the exhaust system at the manifold and hangers and lower it aside. Remove the hanger that runs across under the driveshaft. Remove the exhaust heat shield from under the center of the vehicle.
  4.  
  5. Drain the transmission oil and discard it. Remove the oil filler neck. Disconnect the oil cooler lines at the transmission by unscrewing the flare nuts and plug the open connections.
  6.  
  7. Support the transmission with the proper tools. Separate the torque converter housing from the transmission by removing the Torx® bolts with the proper tool from behind and the regular bolts from underneath. Retain the washers used with the Torx® bolts.
  8.  
  9. Remove bolts attaching the torque converter housing to the engine, making sure to retain the spacer used behind one of the bolts. Then, loosen the mounting bolts for the oil level switch just enough so the plate can be removed while pushing the switch mounting bracket to one side.
  10.  
  11. Remove the bolts attaching the torque converter to the drive plate. Turn the flywheel as necessary to gain access to each of the bolts, which are spaced at equal intervals around it. Make sure to re-use the same bolts and retain the washers.
  12.  
  13. To remove the speed and reference mark sensors, remove the attaching bolt for each and remove each sensor. Keep the sensors clean.
  14.  
  15. Turn the bayonet type electrical connector counterclockwise and then pull the plug out of the socket. Then, lift the wiring harness out of the harness bails.
  16.  
  17. Support the transmission using the proper jack. Then, remove the crossmember that supports the transmission at the rear.
  18.  
  19. Disconnect the transmission shift rod. Then, remove the nuts and then the through bolts from the damper-type U-joint at the front of the transmission.
  20.  
  21. Unscrew the driveshaft spline locking ring at the center mount, if equipped, using the special tool designed for this purpose. Then, remove the bolts and remove the center mount. Bend the driveshaft downward and pull it off the centering pin. Suspend it with wire from the underside of the vehicle.
  22.  
  23. Lower the transmission as far as possible. Then, remove all the Torx® or standard type bolts attaching the transmission to the engine.
  24.  
  25. Remove the small grill from the bottom of the transmission. Then press the converter off with a large prybar passing through this opening while sliding the transmission out.
  26.  

To install:
  1. Install the transmission in position under the vehicle and raise it into position. Observe the following points:
    1. Make sure the converter is fully installed onto the transmission-so the ring on the front is inside the edge of the case. Only use M10x16mm bolts as originally equipped or damage will occur.
    2.  
    3. When reinstalling the driveshaft, tighten the lockring with the proper tool.
    4.  
    5. Make sure to replace the self-locking nuts on the driveshaft flexible joint and to hold the bolts still while tightening the nuts to keep from distorting it.
    6.  
    7. When installing the center mount, preload it forward from its most natural position 0.157-0.236 inches.
    8.  
    9. When reconnecting the bayonet type electrical connector, make sure the alignment marks are aligned after the plug it twisted into its final position.
    10.  
    11. When reinstalling the speed and reference mark sensors, inspect the O-rings used on the sensors and install new ones, if necessary. Make sure to install the speed sensor into the bore marked D and the reference mark sensor, which is marked with a ring, into the bore marked B.
    12.  
    13. Torque the crossmember mounting bolts to 16-17 ft. lbs. (21-23 Nm).
    14.  
    15. If O-rings are used with the transmission oil cooler connections, replace them.
    16.  
    17. Adjust the throttle cables.
    18.  

  2.  

THM-R1
  1. Disconnect the negative battery terminal. Drain the transmission fluid and discard. Do not reuse the old oil. Remove the exhaust system.
  2.  
  3. Mark the mounted position of the crossmember under the driveshaft, the remove.
  4.  
  5. Disconnect the driveshaft from the output flange of the transmission. Loosen the driveshaft spline lockring and remove the center support from the floorpan. Position the driveshaft out of the way and support with wire.
  6.  
  7. Disconnect the shifter cable from the transmission and bracket. Disconnect the connectors from the transmission and the speed sender.
  8.  
  9. Pull out the access plug from the side of the case to reach the torque converter mounting bolts. Use tool 24 1 110 or equivalent to remove the bolts.
  10.  
  11. Place a transmission jack under the transmission and support. Disconnect the oxygen sensor cable and remove the transmission crossmember. Disconnect the oil cooler lines and clamps.
  12.  
  13. Remove the bolts from the transmission to engine joint. Pull the transmission back with the torque converter and lower.
  14.  

To install:
  1. Check the condition of the dowel sleeves and flexplate.
  2.  
  3. Align the torque converter and the flexplate. Place the transmission into position and bolt to the engine. With hexhead bolts, torque the M8 bolts to 17 ft. lbs. (24 Nm), the M10 bolts to 33 ft. lbs. (45 Nm) and the M12 bolts to 57-62 ft. lbs. (78-86 Nm). With Torx® bolts, torque the M8 bolts to 15 ft. lbs. (21 Nm), the M12 bolts to 52 ft. lbs. (72 Nm).
  4.  
  5. Torque the M10x16mm torque converter bolts to 33 ft. lbs. (45 Nm) with tool 24 1 110 or equivalent.
  6.  
  7. Install the oil cooler lines after checking the condition of the O-rings. Install the crossmember and wiring connections.
  8.  
  9. Connect the shifter cable and adjust. Install the driveshaft. Preload the center bearing 0.157-0.236 in (4-6 mm) forward. Torque the flange bolts to 59 ft. lbs. (81 Nm). After completing the installation, torque the spline locking ring to 12 ft. lbs. (17 Nm).
  10.  
  11. Install the crossmember over the driveshaft in the original mounting position. Install the exhaust system and splashguards. Fill the transmission and check the level. Connect the negative battery terminal.
  12.  

 
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