Honda Bmw 5 Service Manual
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--. - - Manual Transmission - V-8 engine: Remove heat shield from left front axle support. < V-8 engine: Remove engine speed reference sensor from transmission. - Where applicable, remove brackets for transmission under- body protection (adjacent to transmission). 4 Support transmission with transmission jack. - Where applicable, remove reinforcing cross brace from below driveshaft at transmission. - Disconnect harness connector from back-up light switch on transmission. - Free harnesses for oxygen sensors and back-up lights from crossmember and transmission. Remove transmission crossmember: Remove transmission mount bolts (A). Remove transmission crossmember bolts (B) Where applicable, remove bolts (C). NOTE- 5-speed transmission shown in illustration. Crossmember assembly for 6-speed transmission is similar. Disconnect driveshaft from transmission and hang to one side. See 260 Driveshaft. I CAUTION- I Do not damage constant velocity joint orprotective boot at rear differential. - 6-cylinder engine: Remove stabilizer bar links and swivel sta- bilizer bar u~wards.
230-1 8 Manual Transmission - Unbolt clutch slave cylinder from side of transmission. Do not disconnect fluid hose. Suspend slave cylinder from chassis using stiff wire. CA UTIOG Unbolt clutch slave cylinder slowly to prevent air being drawn into hydraulic system. . Do not operate clutch pedal with slave cylinder re- moved from transmission. 4 Put BMW special tool 11 7 370 or appropriate sized spacer between engine oil sump and front axle support. Lower trans- mission until engine is supported on spacer. 0 V-8 vehicle: Turn front wheels to prevent strain from being placed on center tie rod. All vehicles: Tilting the engine to lower the transmission can lead to damage to various components due to lack of clearance at rear of engine. Lower transmission slowly - Support front of engine with floor jack. 4 Disconnect shift rod from selector shaft coupling - Disconnect shift console from top of transmission. See 250 Gearshift Linkage. 6-cylinder: Remove transrnisslon mounting Torx-head bolts (arrows). Note length and locatlon of bolts. Remove transrnlssion by pulling backward untll transmls- sion Input shaft clears clutch d~sc spl~nes, then pull down- wards. Lower transmlsslon jack to remove transrnlsslon. - - - - -
Manual Transmission 4 V-8 engine: Remove transmission mounting Tom-head bolts (arrows). Note length and location of bolts. Remove transmission by pulling backward until transmis- sion input shaft clears clutch disc splines, then pull down- wards. Lower transmission jack to remove transmission. - Installation is reverse of removal, keeping in mind the following: When installing a new transmission, be sure to transfer parts from old transmission if applicable. Thoroughly clean input shafl and clutch disc splines. Light- ly lubricate transmission input shaft before installing. * Be sure bellhousing alignment dowel sleeves are located correctly. Replace damaged sleeves. Center rear of transmission in driveshaft tunnel before tightening transmission support bracket. NOTE- In order to avoid difficulties in transmission removal at a fu- ture time, use washers with Torx-head mounting bolts. - Reinstall driveshaft. Use new nuts when mounting driveshaff to transmission/flex disc. See 260 Driveshaft. - Refill transmission with appropriate lubricant before starting or towing car. See Transmission fluid service earlier in this repair group.
Manual Transmission Tightening torques Flex-disc to transmission output flange - Mlo (8.8 grade) 48 Nm (35 ft-lb) - MI0 (10.9 grade) 60 Nm (44 ft-ib) MI2 (8.8 grade) MI2 (10.9 grade) 81 Nm (60 ft-ib) 100 Nm (74 ft-lb) M14 140 Nm (103 ft-lb) Rubber mount to transmission or crossmember 21 Nm (15 ft-lb) (ME) Slave cylinder to transmission 22 Nm (16 ft-lb) Transmission crossmember to chassis or transmission 21 Nm (15 ft-lb) 42 Nm (32 ft-lb) Transmission to engine (Towhead) . M8 22 Nm (16 ft-lb) MI0 43 Nm (32 ft-lb) M12 72 Nm (53 It-lb) Transmission drainlfili plug to transmission 50 Nm (37 It-lb) case
240 Automatic Transmission General . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . Automatic transmission applications . . . . . ,240-2 ATF, draining and filling . . . . . . . . . . . . . . . . 240-7 . . . . . ,240-2 Automatic transmission fluid . . . . . ,240-4 pan and strainer. . . . . . . . . . . . . . . . . . . . . . 240-9 Troubleshooting . . . . . . . . . . . . . . . . . . .240-4 Transmission Removal and Installation . . . . . . . . . . . . . . . . . . . 240-10 Automatic Transmission Fluid Transmission, removing and installing . . . 240-10 (ATF) Service . . . . . . . . . . . . . . . . . . . . . ,240-6 Automatic transmission fluid (ATF) . . . . . . . ,240-6 ATF level, checking . . . . . . . . . . . . . . . . . . ,240-6
240-2 / ~utomatic Transmission This section covers maintenance and replacement of the automatic transmission for E39 models. Automatic transmission internal repairs are not covered. Such repairs require special service equipment and knowl- edge. If it is determined that transmission internal sewice is required, consult an authorized BMW dealer about a factory reconditioned unit or a transmission rebuild. CAUTION- ATF does not circulate unless the engine is running. When towing an automatic transmission vehicle, use a flat bed truck or raise the rear wheels off the ground. Special tools Some special tools are required for the removal and installa- tion of an automatic transmission on the E39 BMW models. While these tools are not absolutely necessary, they are es- pecially helpful when dealing with the removal and replace- ment of the torque converter. 4 Engine support bracket (Tool No. BMW 00 0 200.00 0 208) 4 Transmission jack (Tool No. BMW 00 2 030) 4 Engine support block (V-8 models) 11 7310 (Tool No. BMW 11 7 310)
240-3 Automatic Transmission 4 Engine support block (&cylinder models) (Tool No. BMW 11 7 370) 4 Tran5mission support (for use with transmission jack, A5S 560Z transmission) (Tool No. BMW 24 0 170) 4 Transmission support (for use with transmission jack, A5S 4402 transmission) (Tool No. BMW 24 0 250) 4 Torque converter socket (Tool No. BMW 24 1 100) < Spline bore alignment tool (Tool No. BMW 24 2 300)
Automatic Transmission Automatic transmission applications Automatic transmissions are identified by code letters found on a data plate located on the side or rear of the transmission case. See table below for application information. Automatic transmission applications Model Year Engine Transmission 5281 to 911999 M52 A4S 310R 5281 from 911999 M52 TU A5S 360R 5251 to 312001 M54 A5S 390R 5251 from 312001 M54 ASS 3252 530i to 312001 M54 ASS 390R 530i from 312001 M54 A5S 3252 540i from 111997 M62 TU A5S 4402 Automatic transmission basic components The automatic transmission fitted to BMW 5 Series models is comprised of 3 main elements: 0 Torque converter capable of torque multiplication at an infinitely variable ratio Electrohydraulically controlled valve body 0 Gearbox containing 5 forward speeds and reverse
- .- - Automatic Transmission Electronics are used to control the operation of these auto- matic transmissions. Steptronic transmission functions are also programmed into the transmission control module (TCM). The TCM monitors transmission operation for faults and alerts the driver by illuminating the transmission fault indi- cator on the instrument panel. Diagnostic trouble codes (DTCs) stored in the TCM may be downloaded and interpret- ed by trained technicians using special BMW diagnostic equipment. Some minor automatic transmission problems can be cor- rected by changing the automatic transmission fluid (ATF) and filter. Begin by checking ATF level and condition. Checlc to see if the fluid is dirty or has a burned odor indicating over- heated fluid. The burned odor may be the results of burned discs in theclutch paclts. The friction material from the burned disc can clog valve body passages. NOTE- The E39 automatic transmission is not equipped with a dip- stick. Checking the ATF level must be done while monitoring the ATF temperature with the engine idling. The BMW dealer is equipped with the special equipment to make this check.
240-6 I Automatic Transmission Automatic transmission fluid (ATF) The E39 automatic transmission is filled with either Dexron Ill ATF or Texaco 80728, a life time oil. CA UTIOI\C Use only the transmission fluid that is approved for use by BMW All other fluids will cause non warrantable transmis- I sion damage. Mixing different types of transmission fluids will lead to transmission failure. NOTE- The type of transmission lubricant used can be found on a stickeron the transmission pan. Dexron 111ATF (blacksticker) reads ATF-Oil: Special life time oil (green sticker) reads Life-Time Oil: If in doubt, consult an authorized BMW dealer for alternate fluid use and current information regarding transmission operating fluids. ATF level, checking Check ATF level if there is evidence of a leak, a complaint re- lated to fluid level or afler transmission repairs. The automatic transmission is not equipped with a dipstick. Checking the ATF level requires that the transmission be at operating temperature during the checking procedure. NOTE- Vehicle must be level throughout tests - Drive vehicle to warm up ATF to operating temperature. - Connect BMW diagnostic scan tool DiSplus, MoDiC, GTI or equivalent to determine transmission oil temperature. ATF level checking Fluid temperature 30 - 50°C (85 - 120 F) - With engine running, switch on air conditioning to increase engine idle speed. - Apply parking brake. - While applying foot brake firmly move gear shift selector lever through all gear positions, pausing in each gear briefly.