Removal and installation of transmission (BMW 5 Series E28)

If your vehicle's radio has an anti-theft system, make sure you know the correct activation code before disconnecting the battery. Before disconnecting the wire, refer to Section Anti-theft audio system and instrument cluster language.

If a message in another language appears on the instrument cluster display after connecting the battery, refer to Section 1 for the language setting procedure Anti-theft audio system and instrument cluster language.

Removal

1. Disconnect the negative battery cable.

2. Remove the exhaust system (see chapter Power supply system).

3. Remove the propeller shaft (see chapter Transmission line).

4. Disconnect the gear shift rod (see section Removal and installation the shift lever).

5. Loosen the bolts and remove the gearshift housing mounting brackets. Before doing this, make sure that the gearshift rod is completely disconnected.

6. Disconnect and remove the TDC sensor, speed/position sensor and reverse switch, if applicable, from the transmission (see chapter Ignition system).

7. Remove the clutch slave cylinder (see chapter Clutch). Do not disconnect the clutch hydraulic hose. Secure the slave cylinder with wire.

Do not press the clutch pedal when the slave cylinder is removed from the transmission. If the pushrod is forced out of the cylinder, the slave cylinder may be damaged.

8. Support the transmission with a transmission jack or roller jack and remove the mount nuts.

9. Carefully lower the transmission/engine assembly until it rests on the crossmember.

Never allow the transmission to hang unsupported from the transmission input shaft. This load will damage the clutch and clutch components.

10. Remove the transmission-to-engine mounting bolts. Some bolts may have a socket head; these bolts require a special socket head.

11. Carefully separate the transmission from the engine. Make sure there is no load on the transmission input shaft. Lower the jack to provide enough space to remove the transmission from under the vehicle.

Installation

1. Installation is basically the reverse of removal. Be sure to lightly lubricate the input shaft splines with Microlube GL 261 or similar, then carefully install the transmission onto the engine.

The input shaft splines and clutch disc splines may not match; in this case, to turn the crankshaft slightly, turn the crankshaft pulley with a key.

BMW recommends lubricating the splines of the clutch disc and transmission input shaft only with Microlube GL 261. Otherwise, the clutch disc may stick to the input shaft and gear shifting will be difficult. Microlube GL 261 is available from BMW dealers (BMW part no 81229407436).

If one of the transmission bolts has a socket head, be sure to install washers; installing bolts without washers can result in such tight contact between the cylinder heads and the transmission housing that they will be extremely difficult to unscrew.

2. If the transmission has been drained of oil, be sure to refill it with the correct oil after installation.