Honda Bmw 5 Service Manual

Clutch 
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 
Avoidcontaminating clutch  friction suifaces with 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...

1 Clutch 
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder  model) 
or 
11 2 070 (V-8 model). 
- lnstall SAC pressure plate  on dowel pins  at flywheel.  lnstall 
clutch mounting bolts and  tighten each one turn  at a time until 
pressure plate is  fully seated. Torque to specification. 
Tightening  torques 
Clutch  to flywheel 
- M8 (8.8 grade) 
M8 (10.9  grade)  24 
Nm (18 
ft-ib) 
34 
Nm (25 ft-lb) 
- Slip out clutch centering tool using large  bolt. 
- Remove flywheel locking tool....

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 en- 
sure correct operation  and long  life. Fast  sports driving  ma- 
neuvers 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...

230 Manual Transmission 
General ........................... .23 0.2  Output shaft 
seal. replacing (5-speed 
.... Special tools ........................ .23 0.2  transmission) (transmission installed) 230-10 
Manual transmission  aoolications ....... .23 0.5 Output shaft seal. replacing  (6-speed . . .... transmission) (transmission installed)  230-12 ........ Transmission  Fluid Service .23 0.6 put shaft seal. replacing 
Transmission fluid  level. checking ....... .23 0.6 (transmission ..................

230-2 
I Manual 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 disassemble and 
service the 
internal geartrain. 
Special tools 
BMW  specified  tools are required  for removal and installation 
of  the manual transmission,  as well  as the  removal  and instal- 
lation  of seals  at the transmission input, output,  and...

I Manual ~ransmissionl 
4 Transmission flange counterhold tool 
(Tool  No. BMW  23 0 020) 
4 Transmission  support (for use with  transmission  jack) 
(Tool  No. BMW  23 
0 040) 
Selector  seal extractor 
(Tool  No. BMW  23 
0 210) 
4 Selector seal installation  drifl 
(Tool  No. BMW  23 
0 220) 
4 Input shaft seal  puller (slide  hammer) 
(Tool No. BMW  23 
0 490) 
4 Output shaft flange nut socltet  (27 mm) 
(Tool  No. 23 
1 210) 
4 Output  seal installation drift 
(Tool No. 
BMW 23  2 300)...

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 11 0) 
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 01 0)   

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. Manual  transmission  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 
5281 all 1997-2000 M52, M52 TU ZF S5D 3202 
530i Sedan  2001 
-2002  M54  ZF...

230-6 
Manual Transmission 
Manual transmissions 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. Transmis- 
sions filled with  MTF LT-I lifetime oil are identified with  a yel- 
low  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...