- on models «528», «520» And «520i»: BMW 242/4 four-speed gearbox with Borg-Warner synchromesh in all forward gears;
- on models «525» And «528»: Getrag 262/8 four-speed gearbox with Borg-Warner synchromesh in all forward gears.
Depending on the configuration of the car, a five-speed Getrag gearbox was installed with Porsche synchronizers in all gears.
Gear ratios
Gear ratio of the speedometer drive: 2.5.
Adjustment Data
Axial clearance between the end of the new blocking ring and the end of the ring gear of the synchronizer, mm: 1.0.
Minimum axial clearance between the end face of the blocking ring and the end face of the synchronizer ring gear, mm: 0.8.
Guide rib width, mm:
- «518», «520», «520i»:
- shift forks I, II, III and IV gears: 5-0.03-0.06
- reverse shift forks: 6-0.07-0.145
- «525», «528»:
- shift forks I, II, III and IV gears: 7-0.04-0.098
Axial clearance of primary and secondary shafts, mm:
- «518», «520» And «520i»: 0,50-0,60;
- «525», «528»: 0,17-0,40.
Axial clearance of the intermediate shaft, mm: 0.10-0.20.
The intermediate shaft can be partially disassembled. It has toothed rims of only gears of I and II gears. Pressure testing and pressing of gears of III and IV gears must be carried out on a press.
Effort from presses to and gears of III and IV gears of the intermediate shaft, tf: 10.
The pressing force of the gears of the III and IV gears of the intermediate shaft, preheated to a temperature of 120-150 * 0 («518», «520», «520i») or 150-180°C («525», «528»), ts: 7.
In spare parts, the intermediate shaft is supplied as an assembly.
Roller bearings used in BMW gearboxes «518», «520», «520i»
runout of the secondary shaft, measured at the end and in the place of fastening of the secondary shaft flange, not more than, mm: 0.07.
Gearbox oil
Oil used: EP. SAE 80-90.
Refueling capacity of the gearbox housing, l:
- «518», «520», «520i»: 1,0;
- «520», «525»: 1,1.
Oil level check interval: every 15,000 km (oil should reach the level of the lower edge of the filler hole).
Oil change interval: every 30,000 km (right after the trip).
Tightening torques of the main threaded connections, kgf·m
- Bolts for fastening the gearbox housing to the engine block: M8: 2.5; M10: 4.7.
- Nut of the rear end of the secondary shaft of the gearbox. 10.0.
- Nut of a bolt of fastening of a back cover to a gear case: 2,5.
- Nut for fastening the silent block to the cross member: 4.8.
- Nut of a bolt of fastening of a support of an arm of a suspension bracket to a case of a transmission: 2,5.
- Drain plug: 6.0±1.0.
From model year 1977 on BMW «525», «528» And «528i» a four-speed Getrag type 269/9 gearbox with Borg-Warner brand synchronizers was installed.
Gear ratios
Speedometer drive gear ratio: 2.5.
Axial clearance, mm:
- primary and secondary shafts: 0-0.09;
- intermediate shaft: 0.1-0.2.
Runout of the secondary shaft when measured along the neck, mm: 0.07.
Permissible end runout when measured along the neck and on the fastening of the output shaft flange, mm: 0.07.
Other characteristics of Getrag 269/9 gearboxes are the same as Getrag 262/8 gearboxes.
Tightening torques of the main threaded connections, kgf·m
- M12 bolt for fastening the gearbox housing to the engine block: 7.2-8.0.
- Drain plug 4.0-6.0.
- Nut of a bolt of fastening of a back cover to a gear case: 2,5.
By order, a five-speed Getrag 265/6 gearbox was installed.
Gear ratios
Gear ratio of the speedometer drive: 2.5.
Gearbox housing heating temperature during bearing pressing,°С: 80.
Axial clearance, mm:
- input shaft: 0-0.09;
- secondary shaft: 0-0.09;
- intermediate shaft: 0.1-0.2;
- gears of the 1st gear: 0-0.9;
- sliding clutch of the synchronizer: 0-0.09.
Tightening torques of the main threaded connections, kgf·m
- M12 bolt for fastening the gearbox to the clutch housing: 7.2-8.0.
- Drain and fill plugs: 4.0-6.0.
- Front cover mounting bolts: M8x22: 1.8; M8x30: 2.5.
- Rear cover bolts: 2.5, except for:
- bolt M6x355: 1.0;
- bolt M6x16 (pre-apply a special adhesive such as Loctite to the threads): 0,9.
- Nut of a flange of a secondary shaft: 10,0.
From model year 1980 on BMW «518» And «520» four-speed gearboxes BMW type 242/18 and 242/7 were installed, respectively.
On request for a model «520» a five-speed gearbox with close gear ratios was installed, with a direct V gear of the brand BMW type 245/11.
By order on models «525», «528i» And «535» a five-speed Getrag type 265/5 gearbox with direct V gear was installed.
By order on models «518», «520», «525» And «528i» five-speed «economical» gearboxes respectively of types BMW 245/4, BMW 245/2, 265/4 Getrag, 265/6 Getrag with accelerating V gear.
Gear ratios of gearboxes
Gear ratio of the speedometer drive: 2.5.
Gearbox Specifications
Since model year 1982, the following makes and types of gearboxes have been fitted to the BMW 5 Series:
- «518»: BMW 242/8; 245/4;
- «520»: BMW 242/7; 245/11; 245/2;
- «525i»: Getrag 262/9; 265/5; 265/6;
- «528i»: Getrag 265/5; 265/6.
Tightening torques of the main threaded connections, kgf·m
- Bolt for fastening the gearbox housing to the engine block: M8: 2.2-2.4; M10: 4.7-5.1.
- Bolt for securing the gearbox to the clutch housing: M12: 7.2-8.0.
- Drain plug: 4.0-6.0.
- Nut of a bolt of fastening of a back cover to a gear case: 2,5.
- Nut of fastening of a flange of an output shaft: is put on glue like Loctite «Frenetanch».
- Nut for fastening the silent block to the cross member: M10: 4.3-4.8.
- Bolt for fastening the silent block to the gearbox housing: M10: 4.3-4.8.
- Bolt for fastening the cross member to the floor of the body: M8: 2.2-2.4.
- Bolt for fastening the support of the suspension bracket to the gearbox housing: M8: 2.2-2.4.