Automatic Transmission -- Repair BMW M3 E90

00 Danger of poisoning if oil is ingested/absorbed through the skin

Danger of poisoning!

Ingesting oil or absorbing through the skin may cause poisoning!

Possible symptoms are

1. Headaches
2. Dizziness
3. Stomach aches
4. Vomiting
5. Diarrhoea
6. Cramps/fits
7. Unconsciousness

Protective measures/rules of conduct

1. Pour oil only into appropriately marked containers
2. Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
3. Observe country-specific safety regulations

First aid measures

1. Do not induce vomiting. If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and consult a doctor immediately. If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery position and seek immediate medical attention.

00 Risk of injury if oil comes into contact with eyes and skin

Danger of injury!

Contact with eyes or skin may result in injury!

Possible symptoms are

1. Impaired sight
2. Irritation of the eyes
3. Reddening of the skin
4. Rough and cracked skin

1. Wear protective goggles
2. Wear oil-resistant protective gloves
3. Observe country-specific safety regulations

1. Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-rinsing bottle. If irritation of the eyes persists, consult a doctor.
2. Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor. NOTE: Do not use solvents/thinners.

00 Safety instructions for handling oil

Recycling

Observe country-specific waste-disposal regulations.

Measures if oil is unintentionally released

1. Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work area. Wear personal protective clothing/equipment.
2. Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems, pits, cellars, water and the ground.
3. Limiting spread: Use oil blocks to prevent the surface spread of oil.
4. Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents. NOTE: Do not flush oil away with water or aqueous cleaning agents.

Breakdown of BMW designation

BMW DESIGNATION (A5S 300J)

BMW DESIGNATION (GS6-37BZ)

Manual gearbox

MANUAL GEARBOX DESIGNATION

AUTOMATIC TRANSMISSION DESIGNATION

Special tools required/notes

Note. The universal transmission bracket is introduced for the E60 AWD Suitable for manual and automatic transmissions

Scheme 385

Supporting transmission

Support transmission with special tools 234050 and 002030.

Scheme 386

Note. The transmission retaining bridge 24 0 200 is suitable for both manual and automatic transmissions

Adapt adapters (1) and spindle with thrust piece (3) to transmission.

Adapt length with slide (2).

Screw in spindle (4).

Scheme 387

Necessary preliminary work

1. Remove underbody protection . See «5147490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-490-removing-and-installingreplacing) or «5147491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-491-removing-and-installingreplacing)
2. Remove «REINFORCEMENT PLATE»(/bmw/m3/e90-2007-2013/remont/axle-shafts/#front-axle-repair-e90__31-10-010-removing-and-installingreplacing)
3. Remove heat shields
4. Remove «EXHAUST SYSTEM»(/bmw/m3/e90-2007-2013/remont/exhaust/#exhaust-system-repair-e90__18-00-018-removing-and-installing)
5. Support transmission using Universal BMW transmission take-up.
6. Remove «22 32 050 REPLACING CROSSMEMBER FOR TRANSMISSION MOUNTING (S65)»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-and-gearbox-suspension-repair-e90) or .

1. Unflange propeller shaft from transmission and tie to one side
2. Tasks are described in Removing «PROPELLER SHAFT»(/bmw/m3/e90-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft-repair-e90__26-11-000-removing-and-installing) .

Note. To rotate propeller shaft, unlock parking lock.

Release screws.

Remove transmission bearing block (1).

Tightening torque: 22 32 2AZ .

Scheme 388

Grip output flange (1) with special tool 230020.

Release nut with special tool 232320.

Tightening torque: 28 10 HOUSING WITH ADD-ON PARTS .

Installation note

Replace nut and secure with Loctite 243.

Scheme 389

Detach output flange (1) with special tool 331150 and adapter plate 33 1 154 from output shaft.

Scheme 390

Attach special tool 24 2 353 to output shaft (1).

Graphic shows: Automatic transmission

Scheme 391

Screw in special tool 24 2 351 until it is firmly connected with radial shaft seal.

Pull out radial shaft seal by screwing in special tool 24 2 352.

Graphic shows: Automatic transmission

Scheme 392

Oil sealing lip on radial shaft seal (1). Drive in radial shaft seal (1) with special tool 230410 as far as it will go.

Graphic shows: Automatic transmission

Scheme 393

24..... Manually releasing transmission lock

For various tasks, it is necessary to unlock and lock the transmission lock.

This can be done from inside or underneath the vehicle.

From vehicle interior

1. Refer to «MANUAL EMERGENCY UNLOCKING OF TRANSMISSION LOCK»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-50-001-manual-emergency-release) .

Underneath vehicle

1. Remove «UNDERBODY PROTECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-491-removing-and-installingreplacing)
2. Press lever (1) upwards.

Lock

1. Release lever (1).

Scheme 394

If permanent release is desired

1. Release screw (1).
2. Unlock retainer (2).
3. Release cable from operating lever (4).
4. Tie up operating lever (4) with cable strap.

Lock

Scheme 395

1. Unfasten operating lever (4) and secure cable.

28 60 010 Removing and installing mechatronics (GS7D36SG)

Note. When replacing mechatronics: Import present gearbox data into new mechatronics

1. Read out gearbox data of mechatronics to be replaced
2. Remove «TWIN-CLUTCH GEARBOX»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)

Place twin-clutch gearbox on a suitable surface.

To prevent the gearbox oil from spilling out, make sure that the hydraulic cap point upward.

Remove HYDRAULIC COVER (1).

Scheme 396

Ensure correct installation position.

Press holder (2) together from right and release cable (1).

Installation note

Replace holder, retaining lug must point to the right.

If fitted: Pull out CPA pin (7) to second locking position.

Release connector lock (6) and at same time detach connector (3) from retaining tabs (5) towards right.

Scheme 397

CPA (1) in second locking position.

Installation note

Press CPA pin downward until it is flush with the housing.

Scheme 398

Scheme 399

Place mounting template over mechatronics.

Open screws 1-20.

Note. Replace screws 1-12. Screws 13-20 remain captive on module. Remove mounting template.

Lift mechatronics out of housing.

Remove metal bead gasket.

Scheme 400

Scheme 401

Installing mechatronics

Install a new metal bead gasket.

Install mechatronics.

Fit mounting template.

Installation note

1. Removal and installation of clutch cover: Replace «RADIAL SHAFT SEAL»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair) , O-ring and snap ring.
2. Replacement clutch cover: Replace as a single assembly only (incl. radial shaft seal, O-ring, bearing, retaining plate and snap ring).

1. Remove «TWIN-CLUTCH GEARBOX»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)

To prevent the gearbox oil from spilling out, tilt the gearbox back before removing the clutch cover.

Installation note

After completing work, add gearbox oil and check GEARBOX OIL LEVEL .

Lever snap ring (1) out of housing with a suitable tool.

Installation note

Replace snap ring.

Scheme 402

Graphic shows: Twin-clutch gearbox S65

Slip bush 230390 must be used when clutch cover is removed and installed.

Pull clutch cover with special tool 135250 and adapter 54 0 163 out of housing.

Scheme 403

Graphic shows: Twin-clutch gearbox S65

Remove oil fouling with fluff-free cloth.

Clean snap ring groove before installing clutch plate.

Press clutch cover (1) into housing with arrow pointing up and strike evenly with a plastic mallet.

Then secure clutch cover with snap ring.

Make sure snap ring is correctly seated.

Installation note

Moisten O-ring and radial shaft seal with gearbox oil.

Scheme 404

28 40 020 Removing and installing or replacing clutch support (GS7D36SG)

Necessary preliminary tasks

1. Remove «TWIN-CLUTCH GEARBOX»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
2. Remove «CLUTCH»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair)

Remove OIL PUMP (1).

Unfasten screws (2).

Tightening torque: 28 10 HOUSING WITH ADD-ON PARTS .

Remove clutch support (3).

Installation

Replace screws and seal.

Scheme 405

Scheme 406

28 10 020 Removing and installing or replacing combination sensor (GS7D36SG)

1. Remove «TWIN-CLUTCH GEARBOX»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
2. Remove «CLUTCH»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair)

Release screw (1).

Tightening torque 28 10 HOUSING WITH ADD-ON PARTS .

Release combination sensor (2) from housing.

Disconnect connector (3).

Installation

Replace screw.

Scheme 407

Installation

If holder (5) does have to be released, replace aluminum screw (6).

Tightening torque 28 10 HOUSING WITH ADD-ON PARTS .

Scheme 408

28 10 010 Removing and installing or replacing pump unit (GS7D36SG)

1. Remove «TWIN-CLUTCH GEARBOX»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
2. Remove «CLUTCH»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair)

Release screws (1).

Tightening torque 28 10 HOUSING WITH ADD-ON PARTS .

Remove oil separator (2).

Scheme 409

Release screw (1).

Tightening torque 28 10 HOUSING WITH ADD-ON PARTS .

Disconnect connector (3).

Release combination sensor (2) from housing.

Release screws (1) and (2).

Tightening torque 28 10 HOUSING WITH ADD-ON PARTS .

Installation note

Observe installation position and screw length.

Replace sealing washer on screw (2).

Scheme 410

Release screws (1).

Tightening torque 28 10 HOUSING WITH ADD-ON PARTS .

Release oil pump with pressure pipe (2) and return line (3) from housing.

Installation note

Replace flat seal (4).

During reinstallation O-ring remains on return line.

Scheme 411

Scheme 412

Installation sequence, oil pump

1. Moisten O-ring with transmission oil
2. Position pump in transmission using centering sleeves.
3. Gently insert screws (1) with pressure pipe
4. Press in return line (2) until it audibly snaps into place
5. Screw in oil pump
6. The tightening sequence from 1-8 is mandatory

Scheme 413

Installation note

Centering sleeves must not be damaged or crushed.

Scheme 414

1. Remove «TWIN-CLUTCH GEARBOX»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
2. Remove «CLUTCH COVER»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair)

Scheme 415

Push parking lock lever (1) as far upwards as possible and secure with cable straps (2).

Scheme 416

Rotate drive shaft (1) until holes (2) are directly visible.

Check clearance with a suitable tool.

Scheme 417

Insert special tool 230400 and release clutch by rotating counter-clockwise (approx. 8 turns).

Pull clutch out of housing.

Installation note

Put gearbox in an upright position.

The clutch is correctly installed if the oil pump gear turns.

Install the clutch with special tool 230400 while constantly rotating.

Turn clockwise up to stop, then screw down to torque.

Tightening torque, see 28 40 DOUBLE CLUTCH GEARBOX (DKG) .

Scheme 418

Installation note

Under no circumstances are hammers or other pounding tools to be used when installing the clutch.

The clutch must be slid over the piston rings and onto the clutch support.

Scheme 419

28 60 030 Removing and installing/replacing the hydraulic cap (GS7D36SG)

1. Remove «TWIN CLUTCH TRANSMISSION»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)

Place twin clutch transmission on a suitable surface.

To prevent the gearbox oil from spilling out, make sure that the hydraulic cap point upward.

Release screws.

Remove hydraulic cover (1).

Installation note

Replace seal.

Replace screws.

Installation of hydraulic cap

Make sure seal is exactly seated.

It is mandatory to comply with the specified order of screw connections 1-12.

Tightening torque, see 28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS .

Scheme 420

28 60 514 Replacing mechatronics (GS7D36SG)

Note. When replacing mechatronics: Import present transmission data into new mechatronics

1. Read out transmission data of mechatronics to be replaced
2. Remove «TWIN-CLUTCH GEARBOX»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)

Place twin clutch transmission on a suitable surface.

To prevent the transmission oil from spilling out, make sure that the hydraulic cap points upward.

REMOVE HYDRAULIC CAP (1).

Ensure correct installation position.

Press holder (2) together from right and release cable (1).

Installation note

Replace holder.

Retaining lugs must point to the right.

If fitted: Pull out CPA pin (7) to second locking position.

Release connector lock (6) and at same time detach connector (3) from retaining tabs (5) towards right.

CPA (1) in second locking position.

Installation note

Press CPA pin down until it is flush with the housing.

Place mounting template over mechatronics.

Open screws 1-20.

Note. Replace screws 1-12. Screws 13-20 remain captive on module. Remove mounting template.

Lift mechatronics out of housing.

Remove metal bead gasket.

The new mechatronics ship as shown here, with the shift piston in the neutral position.

Scheme 421

In the gearbox, the gearshift rods have to be set to the neutral position (N) as shown here before the new mechatronics are installed.

Scheme 422

Install a new metal bead gasket.

Install mechatronics.

Fit mounting template.

1. Remove «CLUTCH COVER»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair)

To prevent the transmission oil from spilling out, tilt the gearbox back before removing the clutch cover.

Installation note

After completion of work, check TRANSMISSION OIL LEVEL .

Use only the DUAL-CLUTCH TRANSMISSION FLUID (M DCT DRIVE LOGIC) .

Failure to comply with this instruction will result in serious damage to the twin clutch transmission.

Use a suitable tool to take the radial shaft seal (1) off the clutch cover.

Scheme 423

Place the clutch cover (1) out flat on a workbench.

Coat sealing lips of radial shaft seal with transmission oil.

Press the radial shaft seal (3) lightly into the clutch cover.

Scheme 424

Use special tool 242370 to drive the radial shaft seal into the clutch cover until the sealing ring is flush.

Scheme 425

Use a suitable tool to take the O-ring of the clutch cover out of the groove.

Use a lint-free cloth to remove oil contamination from the O-ring groove.

Installation note

Replace O-ring.

Coat O-ring with transmission oil before installing.

Scheme 426

28 60 020 Replacing wiring harness (GS7D36SG)

1. Remove «TWIN-CLUTCH GEARBOX»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
2. Remove «MECHATRONICS»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair__28-60-010-removing-and-installing)
3. Remove «CLUTCH»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair)

Release screw (1).

Scheme 427

Release screw (1).

Tightening torque: see 28 10 HOUSING WITH ADD-ON PARTS .

Release aluminum screw (6).

Tightening torque: see 28 10 HOUSING WITH ADD-ON PARTS .

Installation

Replace aluminum screw.

Release combination sensor (2) from housing.

Disconnect connector (3).

Removing wiring harness (4) with earth terminal (5) from housing.

See also:
• GEARBOX OIL LEVEL
• DUAL-CLUTCH TRANSMISSION FLUID (M DCT DRIVE LOGIC)
• 5147490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION
• 5147491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
• REINFORCEMENT PLATE
• EXHAUST SYSTEM
• 22 32 050 REPLACING CROSSMEMBER FOR TRANSMISSION MOUNTING (S65)
• PROPELLER SHAFT
• 22 32 2AZ
• 28 10 HOUSING WITH ADD-ON PARTS
• MANUAL EMERGENCY UNLOCKING OF TRANSMISSION LOCK
• PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION)
• TWIN-CLUTCH GEARBOX
• 28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS
• 28 40 DOUBLE CLUTCH GEARBOX (DKG)
• DANGER OF POISONING
• RISK OF INJURY
• HYDRAULIC COVER
• RADIAL SHAFT SEAL
• OIL PUMP
• MECHATRONICS