Withdrawal
Disconnect ground wire (-) battery. The battery is located in the luggage compartment behind the right side trim.
Attention: This erases the contents of memory devices such as the radio code memory. Follow the instructions given in the chapter "Removing and installing the battery".
Raise the car and remove the exhaust system, see p. 66.
Disconnect the reversing light switch wire from the transmission.
Unbolt the disc joint at the gearbox. In order not to strain the disc joint, only loosen the nuts when releasing, do not turn the bolts.
Tilt the cardan shaft to the side and remove it from the centering pins.
Attention: Tie the cardan shaft to the underbody with a wire, do not let it fall.
Unscrew brackets -1- and -2- for lower engine compartment cover and heat shield -3-.
Remove clutch slave cylinder.
Attention: Hydraulic system piping do not disconnect.
Unscrew the pressure rods from the stabilizer on both sides. Keep the ball joint from turning by the flats with a wrench. Tilt stabilizer up.
Attention: Using a garage jack, slightly raise the gearbox and support it. Only then unbolt cross member and gearbox -arrows-.
To prevent damage to the engine oil sump, clamp a suitable piece of wood or BMW tool 117 370 between the sump and the front axle carrier.
Lower the gearbox using a garage jack.
Support the engine from the front with a second garage jack, as it may tip forward after removing the gearbox.
Remove retaining clip -4- from selector rod, remove washers -5- on both sides of selector rod and pull out selector rod.
Using a screwdriver, tilt the axle of the gear selector rod forward. Pull out the axle.
Automatic transmission
Remove from gearbox cable drive gear selection.
Press in the wire clamp and disconnect the electrical connector from the gearbox.
Unbolt the gearbox oil cooler line holder from the engine sump.
Loosen oil cooler lines at gearbox. Remove pipelines.
Caution: Place a suitable vessel under the oil that escapes. To prevent dirt from getting into the oil lines, close their ends with plastic bags and tighten the bags with rubber rings.
Remove opening cover -1- from side of crankcase. Loosen the 3 bolts of the torque converter one after the other with a narrow socket wrench and take care that the bolts do not fall into the crankcase. To ensure that the bolts are opposite the hole, turn the engine crankshaft by the hexagon of the belt pulley.
Support the gearbox on the underside of the vehicle using a garage jack and suitable tool. The gearbox must only be supported through the housing, it must not be supported through the oil pan.
Unbolt gearbox to engine. The location of the mounting bolts is the same as in the case of a manual transmission.
Take measures to prevent the torque converter from slipping out, to do this, at the gearbox housing, attach pliers with the flat side -1- to the converter and thus fix it. If the pliers cannot be inserted, when removing the gearbox, make sure that the converter does not slip out of the gearbox. Remove gearbox from engine.
Screw out the gearbox mounting bolts with a slotted socket wrench (torx key).
Disconnect gearbox from engine and remove downwards together with an assistant.
Installation
Check clutch before installing.
Check the clutch release bearing for ease of movement. Bearing in sliding points lubricate Molykote Longtherm 2.
The slots in the splined engagement of the input shaft can be easily lubricated with Microlube GL 261. Do not over-lubricate as the excess will be thrown onto the friction surfaces of the clutch causing malfunction. The required amount of lubricant does not exceed the size of a grain of rice by volume.
Shift the gear lever into gear.
Attention: Check whether there are guide bushes for centering -1- and -2- between crankcase and gearbox. Raise the gearbox and move it into the clutch in a horizontal position. If, during installation, the drive shaft of the gearbox does not fit into the splines of the clutch disc, then turn the drive shaft by the flange for the propeller shaft by hand until the splines match.
In all cases, place washers under the spline heads of the bolts for fastening the gearbox to the engine.
Tightening torques for slotted head bolts:
- M8 - 25 Nm;
- M10 - 45 Nm;
- M12 - 70 Nm.
Tightening torques for hexagon bolts:
- M8 - 25 Nm;
- M10 - 50 Nm;
- M12 - 80 Nm.
Raise the gearbox and tighten the transverse beam mounting bolts to 25 Nm.
Install clutch slave cylinder.
Lubricate the gear selector rod shaft with Kliiber Polylub GLY B01 and insert. Tilt the mount down.
Insert gear selector rod. Put the washers on the finger and fix the gear selector rod with the locking clip.
Connect the reversing light switch wire.
Automatic transmission
Turn the torque converter at the gearbox so that the lining holes are in the center of the holes in the flywheel. Screw in the special tool (pin).
When docking the engines and gearboxes, three linings fastening at the torque converters coincided with three recesses on the flywheel casing of the engines. Additional alignment is not possible and could result in damage.
Attach the automatic box and carefully insert the pin into the gripper hole. After tightening the gearbox mounting bolts, unscrew the pin from the lining in the forward direction.
Remove the pliers from the crankcase and screw in the 3 bolts of the torque converters through the hole in the crankcase -1-. Tighten bolts to 45 Nm. When replacing, use only original bolts.
Remove the plastic bags that protect against dirt, insert the oil lines into the gearbox with new seals, fix the oil lines in the holder.
Screw the oil line brackets to the engine oil pan.
Connect the electrical connector to the gearbox and secure.
Install and adjust cable drive gear selection.
Pour oil into gearbox.
Install cardan shaft, see next chapter.
Tighten cross member to underbody and gearbox to 50 Nm. Remove the garage jack from under the gearbox.
Screw on the heat shield.
Install the exhaust system.
Screw the stabilizer to the pressure rods with new self-locking nuts and tighten them to a torque of 60 Nm.
Install the lower engine cover.
Connect ground wire (-) battery. Set the clock, tune the radio to transmitting radio stations.