Honda Bmw 5 Service Manual
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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 openings (inset). Grip tool firmly and squeeze special tool handles together. Tighten down special tool knurled screws (arrows). - SAC adjustment ring is now in its original position. 4 Install BMW special tool 21 2 170 on SAC pressure plate. Fit fingers of special tool in slots above dowel pin bores. Tighten down knurled nut (arrow) finger-tight. Screw in T-handle until pressure plate diaphragm spring is pretensioned to stop. < Center clutch disc on flywheel using centering tool. 5-speed transmission: Special tool 21 2 142 6-speed transmission: Special tool 21 2 141 G6S-3762 transmission: Special tool 21 2 201 CAUTION-- Be sure clutch disc is lacing the correct way The disc should be marked kngine side or Transmission side: NOTE- The large bolt in the clutch disc centering tool is used to in- stalland remove the tool only Once the disc is in place on tlie flywheel, remove the bolt to male room for the SACpressure plate.
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. Inspect and clean release bearing lever. Apply a thin coat of grease to release bearing lever lubrication points. lnstall re- lease bearing. Bearing tabs (A) align with contact points (B) on release lever. - Clean release bearing guide sleeve. CA U TIOG Do not grease guide sleeve. If guide sleeve is greased, re- lease bearing may stick to it. - Clean and lightly lubricate clutch disc splines and transmis- sion input shaft splines. - Install transmission. See 230 Manual Transmission Tightening torques Transmission to engine - ME (Torx) . M1O (Torx) . M12 (Torx) 22 Nm (16 ft-lb) 43 Nm (32 ft-lb) 72 Nm (53 it-lb)
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 through all the gears at 3500 - 4000 rpm. On medium grades (approx. 12% and up), start off at ap- prox. 2500 rpm for the first 5 or so times. Tightening torques Clutch slave cylinder to transmission case 22 Nm (16 It-lb) Clutch master cylinder to pedal cluster 10 Nm (89 in-lb) Bralte fluid line to clutch master or slave cylinder 17 Nm (13 ft-lb) Transmission to engine M8 (Torx) 22 Nm (16 fl-lb) . M1O (Torx) 43 Nm (32 ft-lb) MI2 (Torx) 72 Nm (53 it-lb) Flywheel to crankshaft 6 cylinder engine (use new self-loclting bolts) 105 Nm (77 ft-lb) V-8 engine 105 Nm (77 ft-lb) Clutch to flywheel M8 (8.8 grade) M8 (10.9 grade) 24 Nm (18 ft-lb) 34 Nm (25 ft-lb)
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 ............... 230-15 ........... Transmission fluid, replacing .23 0.6 Transmission Removal ................... ..... Transmission External Service .23 0-7 and installation 230-1 Back-up light switch, replacing .......... .23 0- Transmission, removing and installing 230-16 ... Selector shaft seal. reolacina . (transmission installed) ................ .23 0.8
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 selector shafts. If these tools are unavailable, equivalent tools may be substituted. 4 Transmission jack (Tool No, BMW 00 2 030) 4 Seal puller (Tool No. BMW 00 5 01 0) 4 Engine support block (V-8 models) (Tool No. BMW 11 7 31 0) 4 Engine support bloclc (6 cylinder models) (Tool No. BMW 11 7 370)
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) EBlislltliPubiilir~ti corn-ill R~l1l. Rriniurd
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 S5D 3202 540i Sedan 1997-2002 M62, M62 TU ZF S6S 420G NOTE- Do not rely on casting numbers for transmission code identification. Table b. Manual transmission gear ratios - Getrag Gear Getrag S5D 250G ZF S5D 3202 S6S 420G 5-speed 5-speed 6-speed 6 th 0.83 Reverse 4.04 3.89 3.75 Final drive 3.15 523: 3.23 2.81 5281 530i: 2.93
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 transmission filler plug. CAUTION- Make sure the car is stable and well supporfedat all times. 4 Remove side filler plug (B). Insert finger into hole to check fluid level. If fluid level is up to bottom of filler hole (finger is wetted by transmission fluid), level is correct. NOTE- * Check and fill transmission with car on level surface. 5-speed transmission shown in illustration. 6-speed trans- mission is similar. - Install and torque filler plug. Tightening torque Transmission drain or fill plug to transmission case SO Nm (37 it-lb) Transmission fluid, replacing - Drive vehicle for a few miles to warm transmission. - Raise and safely support vehicle to access drain plug. CAUTION- Make sure the car is stable and well supported at all times. Use a professional automotive lift orjack stands designed for the purpose. A floor jack is not adequate support. Check that the fill plug is not seizedprior to draining transmission fluid.