Honda Bmw 5 Service Manual

230-7 
Manual Transmission 
Place drain pan under  transmission  and remove drain  plug 
(A) at bottom  of transmission. 
Drain  fluid. 
lnstall  and torque  drain plug. 
Remove  fill plug 
(6) from  side of transmission. 
Slowly fill  transmission  with  fluid until fluid overflows fill 
hole. 
lnstall  and torque fluid  fill 
plug. 
NOJE- 
5-speed  transmission shown  in illustration.  6-speed trans- 
mission  is similar. 
Fluid  capacity 
Initial fill 
newirebuilt Transmission  unit  Fluid change...

Manual Transmission Selector shaft seal, replacing 
(transmission  installed) 
- Put transmission into second  gear. 
- Raise and safely support  vehicle. 
WARNING- 
Make sure  the car  is stable  and well supported  at all times. 
Use  a professional  automotive lift 
orjack stands designed  for 
the  purpose. 
A floorjack is not  adequate  support 
- 6-speed transmission:  Remove rear  engine splash shield 
- Remove exhaust system and heat shields. See 180 Exhaust 
System. 
- Support transmission with...

230-9 
Manual ~ransmissionl 
Carefully pry out selector  shaft oil seal with  BMW special  tool 
23 
0 210, or with  a narrow  seal remover  or small screwdriver. 
Coat  new selector shaft seal  with transmission fluid.  Drive 
new  seal  in flush  with housing. Use 
BMW special  seal instal- 
lation tool 
23 0 220 or  equivalent  and a soft-faced  (plastic) 
hammer. 
- Remainder  of installation  is reverse  of removal,  noting the fol- 
lowing: 
Install  driveshaft  using new 
loclc nuts. 
Check...

230-1 0 
I Manual Transmission 
Output shaft seal, replacing  (5-speed 
transmission) (transmission installed) 
- Raise and safely support  vehicle. 
WARNING - 
Make sure the car is stable  and well supported  at all times. 
Use a professional  automotive 
lilt orjack stands designed 
for  the  purpose. 
A floorjack is not  adequate support. 
- Remove exhaust system  and heat shields. See 180 Exhaust 
System 
Support transmission  with transmission jack. 
Disconnect driveshafi  at transmission output...

230-1 1 
Manual ~ransmissionl 
Coat new seal  with transmission  fluid.  Use seal installation 
drift (see  table below) to drive  seal into position until it is flush 
with  housing. 
Output seal drives 
Transmission 
BMW special  tool 
Getrag S5D 250G 240110 
ZF S5D 3202 23 2 300 
inspect sealing surface  on output flange.  Replace if flange 
surface  is worn or  damaged. 
Heat output flange  to about 176 
F (80 C) to  aid in installa- 
tion.  This  can be  done by placing  flange in hot water. Rein-...

230-12 
/ Manual Transmission 
Output shaft seal, replacing (6-speed 
transmission) (transmission installed) 
- Raise  and safely  support vehicle. 
WARNING- 
Make sure the car  is stable  and well supported  at all times. 
Use  a professional  automotive lift 
orjack stands designed for 
the  purpose. 
A floorjack is not  adequate  support. 
- Remove exhaust  system and heat shields. See 180 Exhaust 
System. 
- Support transmission with transmission jack 
- Disconnect driveshaft at transmission  output...

230-1 3 
Manual ~ransmissionl 
I 4 Remove shims under collar nut  and set aside. 
- Use  puller  to remove output flange 
4 Use  BMW special tool 00 5 010 or other suitable  seal puller 
to  remove seal from transmission  housing. 
4 Coat  new seal with transmission fluid.  Use seal installation 
drift,  BMW special tool 23  2 480 or equivalent, to drive seal 
into housing as far as  it will  go. 
- Inspect sealing surface  on output flange.  Replace if worn or 
damaged. 
- Coat sealing  lip  of seal,...

230-14 
I Manual Transmission 
If installing  new output  flange:  Recalculate  thickness of 
shims based  on difference  in height between output shaft 
surface  and collar  nut support  surface.  Shims must  be within 
the  output  flange preload  specification  below the collar  nut 
support  surface. 
Output flange preload  Difference  between heights  of shaft  and output  0.05 
- 0.22 mm 
flange  sealing 
suriace MINUS  thickness  of shims  (0.002 - 0.009 in) 
NOTE- 
Shims  are available in...

Manual Transmission 
Input shaft seal, replacing 
(transmission removed) 
- Remove transmission  from vehicle as  described later in this 
group. 
- Remove clutch release  bearing end release bearing  lever 
from  inside  bellhousing. 
4 Remove bolts  (arrows) for clutch  release-bearing guide 
sleeve,  noting bolt  lengths 
(Getrag trensmission  shown). 
Remove sleeve  and any spacers (shims) under  it. 
Two  covered  removal holes  (arrows) are present  in seal. 
Thread  BMW special tool 
23 0 490 or...

Manual Transmission 
- Thoroughly  clean guide sleeve mounting bolts, sealing  sur- 
faces,  and threads. Apply 
Loctite8243 or equivalent  thread 
locking compound  to guide sleeve bolts. Reinstall  guide 
sleeve  and 
spacer(s). 
Tightening torques 
Guide sleeve  to transmission  case 
M6  10 Nm (89 in-lb) 
* M8 x 22 18 Nm (13 ft-lb) 
- Max30 25 Nm (18 ft-lb) 
- Reinstall transmission. 
TRANSMISSION REMOVAL AND 
~NSTALLATION 
Removal  and installation  of the  transmission is  best accorn- 
plished on...