BMW 3 Series Service Manual (E39)
.pdfClutch
Clutch, installing (used SAC components)
When reinstalling a previously used self-adjusting clutch (SAC), special tools are needed to reset the self-adjusting ring to its original position.
CAUTIOI\C
Avoidcontaminatingclutch frictionsuifaceswith oilorgrease. Do not touch these suifaces.
-Place SAC pressure plate on clean worlc suriace.
4 Place BMW special tool 21 2 180 on pressure plate
Note that locating hoolts of special tool engage pressure plate adjusting ring openings (inset).
Grip tool firmly and squeeze special tool handles together.
-Tighten down special tool knurled screws (arrows). SAC adjustment ring is now in its original position.
4 Install BMW special tool 21 2 170 on SAC pressure plate.
Fit fingers of special tool in slots above dowel pin bores.
Tighten down knurled nut (arrow) finger-tight.
Screw in T-handle until pressureplate diaphragm spring is pretensioned to stop.
<Center clutch disc on flywheel using centering tool.
5-speed transmission: Special tool 21 2 142
6-speed transmission: Special tool 21 2 141
G6S-3762 transmission: Special tool 21 2 201
CAUTION--
Be sure clutch disc is lacingthe correct way The disc should be marked 'kngineside" or 'Transmissionside':
NOTE-
The large bolt in the clutch disc centering tool is used to installandremove the tool only Once the disc is inplace on tlie flywheel, remove the bolt to male room for the SACpressure plate.
Self-adjusting clutch (SAC), breaking in
With normal driving, 800 to 1000 gearshifts are required to break in the clutch.
Break in the SAC gradually, with light to medium loads, to ensure correct operation and long life. Fast sports driving maneuvers may destroy a new clutch.The following break-in procedure helps to create the correct coefficient of friction.
Drive normally on level grade. Starting speeds on level grade may be up to 2000 rpm.
Upshift and downshift through all the gears at 3500 - 4000 rpm.
On medium grades (approx. 12% and up), start off at approx. 2500 rpm for the first 5 or so times.
Tightening torques |
|
Clutch slave cylinder to transmission case |
22 Nm (16 It-lb) |
Clutch master cylinder to pedal cluster |
10 Nm (89 in-lb) |
Bralte fluid line to clutch master or slave cylinder |
17 Nm (13 ft-lb) |
Transmissionto engine |
|
M8 (Torx) |
22 Nm (16 fl-lb) |
.M1O (Torx) |
43 Nm (32ft-lb) |
MI2 (Torx) |
72 Nm (53 it-lb) |
Flywheel to crankshaft |
|
6 cylinder engine (use new self-locltingbolts) 105 Nm (77 ft-lb) |
|
V-8 engine |
105 Nm (77 ft-lb) |
Clutch to flywheel |
|
M8 (8.8 grade) |
24 Nm (18 ft-lb) |
M8 (10.9 grade) |
34 Nm (25 ft-lb) |
230-2
IManual Transmission
This repair group covers external transmission service, including removal and installation of the transmission unit. Internal transmission repair is not covered. Special tools and procedures are required to disassembleand servicethe internal geartrain.
Special tools
BMW specified tools are requiredfor removaland installation of the manualtransmission, as well as the removaland installation of seals at the transmission input, output, and selector shafts. If these tools are unavailable,equivalenttools may be substituted.
4 Transmission jack
(Tool No, BMW 00 2 030)
4Seal puller
(Tool No. BMW 00 5 010)
4Engine support block (V-8models) (Tool No. BMW 11 7 310)
4 Engine support bloclc (6 cylinder models) (Tool No. BMW 11 7 370)
230-4
/Manual Transmission
4 Output shaft flange nut socket (36 mm) (Tool No. BMW 23 2 320)
Seal installation drift
(Tool No. BMW 23 2 340,23 2 430,24 0 110)
4 Output shaft seal installation drift
(6-speed transmission) (Tool No. BMW 23 2 480)
4 Input shaft seal installation tools (6-speed transmission) (Tool No. BMW 23 2 490 (23 2 491 and 23 2 492))
<Output flange installation tool
(6-speed transmission) (Tool No. BMW 23 3 010)
230-5
Manual Transmission
Manual transmission applications
Manual transmissions used are based on engine application. See Table a. Manual transmission applications. For gear ratio specifications, seeTable b. Manualtransmission gear ratios.
Table a. Manual transmission applications |
|
||
Model |
Year |
Engine |
Transmission |
5251 |
|
|
|
Sedan |
2001-2002 |
M54 |
Getrag S5D 250G |
Sport Wagon |
2001-2002 |
M54 |
ZF S5D 3202 |
5281all |
1997-2000 |
M52, M52 TU ZF S5D 3202 |
|
530i Sedan |
2001-2002 |
M54 |
ZF S5D 3202 |
540i Sedan |
1997-2002 |
M62, M62 TU |
ZF S6S 420G |
NOTE-
Do not rely on casting numbers for transmission code identification.
Table b. Manual transmission gear ratios |
|
||
|
|
- |
|
|
|
|
Getrag |
Gear |
Getrag S5D 250G ZF S5D 3202 |
S6S 420G |
|
|
5-speed |
5-speed |
6-speed |
6 th |
|
|
|
0.83 |
Reverse |
4.04 |
3.89 |
|
3.75 |
Final drive |
3.15 |
523: |
3.23 |
2.81 |
|
|
5281 |
530i: 2.93 |
|
230-6
Manual Transmission
Manualtransmissions installed in the 5 Series are normally filled with a "Lifetime" manual transmission fluid (BMW MTF LT-I) and do not require periodic fluid changes. Transmissions filled with MTF LT-I lifetime oil are identified with a yellow label near the transmission fill plug labeled "Lifetime Oil MTF-LT-1".
Transmission fluid level, checking
-Drive vehicle for a few miles to warm transmission.
-Raise and safely support vehicle to access transmission filler plug.
CAUTION-
Make sure the car is stable and well supporfedat all times.
4 Remove side filler plug (B). Insert finger into hole to check fluid level. If fluid level is up to bottom of filler hole (finger is wetted by transmission fluid), level is correct.
NOTE-
*Check and fill transmission with car on level surface.
5-speed transmissionshown in illustration. 6-speed transmission is similar.
-Install and torque filler plug.
Tightening torque |
|
Transmission drain or fill plug |
|
to transmission case |
SO Nm (37it-lb) |
Transmission fluid, replacing
-Drive vehicle for a few miles to warm transmission.
-Raise and safely support vehicle to access drain plug.
CAUTION-
Make sure the car isstable andwellsupportedat all times. Use a professionalautomotive lift orjack stands designed for the purpose. A floorjack is not adequatesupport.
Check that the fill plug is not seizedprior to draining transmission fluid.