Double Clutch Gearbox - Repair BMW M3 E90

28 00.. Checking/topping up fluid level in twin-clutch gearbox (GS7D36SG)

Checking fluid level

1. Call up Service functions (Drive) in BMW diagnosis system
2. Carry out fluid level check in accordance with instructions

Installation

Tighten down filler plug using

Scheme 315

1. Hexagon wrench 8 A/F
2. Torque wrench
3. Socket 8 A/F

Topping up transmission fluid after a repair

Stand vehicle on a level surface and secure against rolling off.

Scheme 316

1. Open fluid adjusting screw (1). If fluid emerges, close screw again immediately If no fluid emerges, top up until fluid emerges and close fluid adjusting screw (1) again NOTE: If fluid has been replenished here, a further refill must be carried out during the actual fluid adjustment
2. Connect diagnosis system and start service functions (drive).
3. Start engine (drive position N or P)
4. Record transmission temperature using Tester
5. (Drive position P)
6. Permissible starting temperature < or = 32°C
7. Idle speed: maintain at approx. 2000 RPM for 1 minute.
8. Open fluid adjusting screw (1)
9. Fill until fluid emerges Max. transmission fluid temperature 40°C Insert screw Installation: Replace screw.

28 00 101 Installing replacement transmission (GS7D36SG)

Drain gear oil at oil drain plug.

Tightening torque: see 28 00 DOUBLE CLUTCH GEARBOX .

Recycling

Catch and dispose of escaping transmission fluid.

Observe country-specific waste-disposal regulations

Replacement transmission is supplied filled with transmission fluid.

Use only the approved gear oil for dual clutch transmission.

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

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) .

Note. Release screws. Remove and convert transmission bearing block (1).

Scheme 317

Picture shows N54.

Modify all transportation retainers.

Convert all cable holders.

Convert all seal plugs.

Convert protective cap on input shaft.

Transmission identification

Scheme 318

1. refer to BMW Parts Department.
2. On type plate

28 50 001 Manual emergency release of transmission lock (GS7D36SG) S65

In the event of a power supply interruption, e.g. flat battery or electrical fault, the transmission lock must be manually released, otherwise the wheel will be locked and the vehicle cannot be moved.

Press installation frame of gaiter (1) a little from front to rear and release gaiter from center console.

Scheme 319

Insert a suitable tool in cover (1) and fold open towards front.

Scheme 320

Insert tool in lock (1) and fold towards rear.

Transmission lock is released.

Scheme 321

Scheme 322

0 General information Transmission designations, complete transmission, check fluid level, mechatronics

1. Transmission housing, front section
2. Transmission housing, rear section
3. Cooling line connection
4. Transmission connector
5. Mechatronics module
6. Transmission interlock
7. Radial seal For output flange
8. Output flange
9. Output shaft

28 02 020 Removing and installing or replacing transmission oil sump (GS7D36SG)

Recycling

Catch and dispose of escaping transmission oil.

Observe country-specific waste disposal regulations.

Necessary preliminary work

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

Remove oil drain plug (1).

Drain off transmission oil.

Scheme 323

Unscrew all bolts.

Remove transmission oil sump (1).

Installation note

Clean sealing ring groove with fluff-free cloth.

Scheme 324

Installation note

Insert screws until contact with screw heads is made.

Screw down to torque in specified sequence (1-14).

Tightening torque, see 28 00 4AZ in 28 00 DOUBLE CLUTCH GEARBOX .

28 00 001 Removing and installing twin clutch transmission (GS7D36SG) S65

Special tools required

After completion of work, check TRANSMISSION OIL LEVEL .

Use only the approved gear oil for dual clutch transmission.

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

Apply a thin coating of "MI - Setral-43N" grease to transmission input shaft!

Necessary preliminary tasks

1. Read out transmission data of the gearbox to be replaced with the BMW diagnosis system
2. Clamp off battery . See «INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and) or «DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)
3. Remove both left/ right suspension cross-brace. See «51 71 345 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION CROSSBRACE»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-345-removing-and-installingreplacing) .
4. 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) at front and rear.
5. Remove «REINFORCEMENT PLATE»(/bmw/m3/e90-2007-2013/remont/axle-shafts/#front-axle-repair-e90__31-10-010-removing-and-installingreplacing)
6. Remove «COMPLETE EXHAUST SYSTEM»(/bmw/m3/e90-2007-2013/remont/exhaust/#exhaust-system-repair-e90__18-00-018-removing-and-installing)
7. Remove «PROPELLER SHAFT»(/bmw/m3/e90-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft-repair-e90__26-11-000-removing-and-installing)

Release screw (1).

Unlock and disconnect plug (2).

Release cable (3) from holders.

Scheme 325

Release screws (1).

Remove retaining plate (2).

Scheme 326

Release screws (1).

Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .

Release screw (2).

Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .

Remove input speed sensor (3).

Scheme 327

Release screw (1).

Unlock retainer (2).

Release cable from lever and holder.

Scheme 328

Release screw (1).

Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .

Disconnect hydraulic lines (2) to transmission fluid cooler.

Close off hydraulic lines and connecting bores on thermostat with plugs.

Scheme 329

Installation

Replace sealing rings (1).

Scheme 330

Supporting transmission

Support transmission with special tools 23 4 050 FIXTURE , 00 2 030 DEVICE .

Secure transmission to mounting with tensioning strap (1).

After completion of work, check transmission oil level.

Scheme 331

Bolt special tool 11 9 990 DEVICE with bolt (1) to front axle support.

Bolt (2) is required to secure the engine in the correct position.

Scheme 332

Adjust special tool 11 9 990 DEVICE until dimension A=50 mm is obtained between front axle support and tensioner.

Scheme 333

Remove CROSSMEMBER FOR TRANSMISSION MOUNTING (S65) .

Release screw (1).

Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .

Remove transmission fluid thermostat (2).

Close off connecting bores on transmission and thermostat with plugs.

Scheme 334

Installation

Replace sealing rings.

Clean screw thread.

Screw (2) must be coated with Loctite 243 prior to installation.

Scheme 335

1. Unlock and disconnect plug (1) by turning.
2. Do not touch pins.
3. Release cable from retainers.
4. Insert special tool «24 2 390 CAP»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-special-tools) in sealing sleeve.

Operations are described in

NOTES ON MECHATRONICS

Scheme 336

Installation

Pay attention to routing and length of wiring harness.

Insert special tool 24 2 390 CAP in sealing sleeve (1).

Scheme 337

Release screws (1).

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

Pull oil - coolant heat exchanger towards rear out of guide (2).

Installation

Oil-coolant heat exchanger and transmission oil thermostat remain on vehicle during removal of transmission.

Scheme 338

Release wiring harness.

Installation

1. Connection (1), monitoring sensor, left: shortened corrugated tubing (wiring visible between end of corrugated tubing and plug housing).
2. Connection (2), monitoring sensor, right: cable lug with designation "R", corrugated tubing closed off at plug housing (wiring not visible).

Release screws (1) and (2).

Tightening torque, see 28 00 DOUBLE CLUTCH GEARBOX .

Note. Bolt (3) must not be released. Bolt (3) is for securing the starter.

Scheme 339

Installation

Apply a thin coating of "MI-Setral-43N" grease to transmission input shaft.

BMW part number EU: 83 23 2 152 082

BMW part number USA: 83 23 2 152 081

28 00 060 Replacing output flange radial shaft seal (GS7D36SG)

Special tools required

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 «CROSSMEMBER FOR TRANSMISSION MOUNTING (S65)»(/bmw/m3/e90-2007-2013/remont/mechanical/#engine-and-gearbox-suspension-repair-e90) .

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 .

Grip output flange (1) with special tool 23 0 020 HOLDER .

Release nut with special tool 23 2 320 SOCKET WRENCH INSERT .

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

Installation note

Replace nut and secure with Loctite 243.

Scheme 340

Detach output flange (1) with special tool 33 1 150 DEVICE and adapter plate 33 1 154 from output shaft.

Scheme 341

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

Graphic shows: Automatic transmission

Scheme 342

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 343

Oil sealing lip on radial shaft seal (1). Drive in radial shaft seal (1) with special tool 23 0 410 MANDREL as far as it will go.

Graphic shows: Automatic transmission

Scheme 344

28 60 000 Replacing pressure filter (GS7D36SG)

Special tools required

Recycling

Catch and dispose of escaping transmission oil.

Observe country-specific waste disposal regulations.

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) at front and rear.
2. Remove «REINFORCEMENT PLATE»(/bmw/m3/e90-2007-2013/remont/axle-shafts/#front-axle-repair-e90__31-10-010-removing-and-installingreplacing)
3. Remove «EXHAUST SYSTEM»(/bmw/m3/e90-2007-2013/remont/exhaust/#exhaust-system-repair-e90__18-00-018-removing-and-installing)
4. Remove «PROPELLER SHAFT»(/bmw/m3/e90-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft-repair-e90__26-11-000-removing-and-installing)

Only on S65

Release screw (1).

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

Disconnect hydraulic lines (2) to transmission oil cooler.

Close off lines with plugs.

Installation note

Replace sealing rings.

Supporting transmission

Support transmission with special tools 23 4 050 FIXTURE , 00 2 030 DEVICE .

Secure transmission with tensioning strap (1).

After completion of work, check transmission oil level.

Lower engine with transmission until pressure filter lid (1) is accessible.

Remove retainer (2).

Installation note

Replace retainer.

Scheme 345

Lever out lid (1) with sealing ring.

Installation note

Replace lid with sealing ring.

Lubricate sealing ring with transmission oil before installing.

Scheme 346

Remove pressure filter (1).

Scheme 347

28 10 000 Replacing suction filter (GS7D36SG)

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

Recycling

Catch and dispose of escaping transmission fluid.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Remove «TRANSMISSION FLUID SUMP»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-02-020-removing-and-installing)

Release screw (1).

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

Pull suction jet pump (2) out of housing.

Installation

Moisten seals with transmission oil before installing.

Replace suction jet pump.

Scheme 348

Release screws (1) and (2).

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

Pull suction filter out of housing.

Installation

Moisten seal with transmission oil before installing.

Scheme 349

28 10 020 Removing and installing or replacing combination sensor (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/#double-clutch-gearbox-repair__28-40-010-removing-and-installing)

Release screw (1).

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

Release combination sensor (2) from housing.

Disconnect connector (3).

Installation

Replace screw.

Scheme 350

Installation

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

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

Scheme 351

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

Necessary preliminary work

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/#double-clutch-gearbox-repair__28-40-010-removing-and-installing)

Release screws (1).

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

Remove oil separator (2).

Scheme 352

Release screw (1).

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

Disconnect connector (3).

Release combination sensor (2) from housing.

Release screws (1) and (2).

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

Installation note

Observe installation position and screw length.

Replace sealing washer on screw (2).

Scheme 353

Release screws (1).

Tightening torque see 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 354

Scheme 355

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 356

Installation note

Centering sleeves must not be damaged or crushed.

Scheme 357

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

Recycling

Catch and dispose of escaping transmission fluid.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Remove «TRANSMISSION FLUID SUMP»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-02-020-removing-and-installing)

Release screw (1).

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

Pull suction jet pump (2) out of housing.

Installation

Moisten seals with transmission oil before installing.

Replace suction jet pump.

Release screws (1) and (2).

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

Pull suction filter out of housing.

Installation

Moisten seal with transmission oil before installing.

28 40 000 Removing and installing or replacing clutch cover (GS7D36SG)

Special tools required

Installation note

1. Removal and installation of clutch cover: Replace «RADIAL SHAFT SEAL»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-40-050-replacing-radial-shaft) , 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).

Necessary preliminary work

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 358

Graphic shows: Twin-clutch gearbox S65

Slip bush 23 0 390 BUSH must be used when clutch cover is removed and installed.

Pull clutch cover with special tool 13 5 250 PULLER and adapter 54 0 163 out of housing.

Scheme 359

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 360

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: see 28 10 HOUSING WITH ADD-ON PARTS .

Remove clutch support (3).

Installation

Replace screws and seal.

Scheme 361

Scheme 362

28 40 010 Removing and installing or replacing twin clutch (GS7D36SG)

Special tools required

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 COVER»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#automatic-transmission-repair)

Scheme 363

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

Scheme 364

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

Check clearance with a suitable tool.

Scheme 365

Insert special tool 23 0 400 KEY 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 23 0 400 KEY while constantly rotating.

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

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

Scheme 366

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 367

28 40 050 Replacing radial shaft seal for clutch cover (GS7D36SG)

Special tools required

Necessary preliminary work

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 approved gear oil for dual clutch transmission.

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 368

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 369

Use special tool 242 370 to drive the radial shaft seal into the clutch cover until the sealing ring is flush.

Scheme 370

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 371

28 60.. Notes on mechatronics (GS7D36SG)

Special tools required

Unscrew plug (1) and disconnect.

Insert special tool 24 2 390 CAP in sealing sleeve (1).

28 60 010 Removing and installing mechatronics (GS7D36SG)

Note. When replacing mechatronics

1. Import present gearbox data into new mechatronics

Necessary preliminary work

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 372

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 373

CPA (1) in second locking position.

Installation note

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

Scheme 374

Scheme 375

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 376

Scheme 377

Installing mechatronics

Install a new metal bead gasket.

Install mechatronics.

Fit mounting template.

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

Necessary preliminary work

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 378

28 60 025 Replacing O-ring for wiring harness (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) .

Transmission must be cleaned around the sealing cup to prevent dirt penetration.

Failure to comply with this instruction may result in serious damage to the twin-clutch gearbox!

Release screw (1).

Scheme 379

Pull out sealing cup (1).

Remove sealing ring (2).

Clean sealing cup (1).

Scheme 380

Attach new sealing ring (1) to sealing cup.

Carefully pull sealing ring over screwing flange and install.

Scheme 381

28 60 514 Replacing mechatronics (GS7D36SG)

Note. When replacing mechatronics

1. Import present transmission data into new mechatronics

Necessary preliminary tasks

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 382

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 383

Installing mechatronics

Install a new metal bead gasket.

Install mechatronics.

Fit mounting template.

Special tools required

Recycling

Catch and dispose of escaping transmission oil.

Observe country-specific waste disposal regulations.

Necessary preliminary work

1. Remove underbody protection See «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 «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) at front and rear
2. Remove «REINFORCEMENT PLATE»(/bmw/m3/e90-2007-2013/remont/axle-shafts/#front-axle-repair-e90__31-10-010-removing-and-installingreplacing)
3. Remove «EXHAUST SYSTEM»(/bmw/m3/e90-2007-2013/remont/exhaust/#exhaust-system-repair-e90__18-00-018-removing-and-installing)
4. Remove «PROPELLER SHAFT»(/bmw/m3/e90-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft-repair-e90__26-11-000-removing-and-installing)

Only on S65

Release screw (1).

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

Disconnect hydraulic lines (2) to transmission oil cooler.

Close off lines with plugs.

Installation note

Replace sealing rings.

Supporting transmission

Support transmission with special tools 23 4 050 FIXTURE , 00 2 030 DEVICE .

Secure transmission with tensioning strap (1).

After completion of work, check transmission oil level.

Lower engine with transmission until pressure filter lid (1) is accessible.

Remove retainer (2).

Installation note

Replace retainer.

Lever out lid (1) with sealing ring.

Installation note

Replace lid with sealing ring.

Lubricate sealing ring with transmission oil before installing.

Remove pressure filter (1).

28 60 020 Replacing wiring harness (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 «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 384

Release screw (1).

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

Release aluminium screw (6).

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

Installation

Replace aluminium screw.

Release combination sensor (2) from housing.

Disconnect connector (3).

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

Risk of damage to sealing surface.

See also:
• 28 00 DOUBLE CLUTCH GEARBOX
• TRANSMISSION FLUID COOLER TOGETHER WITH LINES
• UNDERBODY PROTECTION
• INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
• DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD
• 51 71 345 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION CROSSBRACE
• 5147490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION
• REINFORCEMENT PLATE
• COMPLETE EXHAUST SYSTEM
• PROPELLER SHAFT
• DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES
• 23 4 050 FIXTURE
• 00 2 030 DEVICE
• 11 9 990 DEVICE
• CROSSMEMBER FOR TRANSMISSION MOUNTING (S65)
• 24 2 390 CAP
• 28 10 HOUSING WITH ADD-ON PARTS
• 22 32 2AZ
• 33 1 150 DEVICE
• PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION)
• GEARBOX OIL LEVEL
• 13 5 250 PULLER
• CLUTCH
• OIL PUMP
• 28 40 DOUBLE CLUTCH GEARBOX (DKG)
• AUTOMATIC TRANSMISSION - OPERATING FLUIDS
• 28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS
• APPROVED TRANSMISSION OIL
• MECHATRONICS
• TRANSMISSION OIL LEVEL
• TWIN-CLUTCH GEARBOX
• NOTES ON MECHATRONICS
• TRANSMISSION FLUID SUMP
• CLUTCH
• RADIAL SHAFT SEAL
• HYDRAULIC COVER