Manual Transmission - Repair - e90 BMW M3 E90

00 11 229 Changing/topping up/checking gear oil in manual transmission

Recycling

Catch and dispose of gear oil with suitable equipment.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

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) .

Draining gear oil

Scheme 252

1. Open oil drain plug (1) and drain gear oil
2. Activate gear oil pump using DIS Tester for approx. 30 seconds The residual oil is pumped out of the pump circuit of the transmission oil cooler into the transmission housing and flows off
3. Allow gear oil to flow off sufficiently
4. Clean oil drain plug (1) and screw in Tightening torque «23 00 4AZ»(ref-381603-S36549337812010123000000) .

Release screw (1).

Tightening torque 23 41 17AZ .

Check transmission oil screen, replace if necessary.

Installation

Replace sealing ring

Scheme 253

Adding gear oil.

1. Undo oil filler plug (2).
2. Pour in oil until it overflows at inspection opening.
3. Check gear oil level (see below).

Checking gear oil level

Note. Can also be carried out individually - without an oil change! Activate gear oil pump via DIS Tester. Open oil filler plug. Top up gear oil with pump running to lower edge of filler opening. Refit oil filler plug. Tightening torque 23 00 4AZ . Switch off pump activation.

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.

23 00 037 Installing replacement transmission (GS6-53BZ) S65

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

Catch and dispose of escaping transmission fluid.

Observe country-specific waste-disposal regulations

1. Drain gear oil at oil drain plug. Tightening torque: «23 00 4AZ»(ref-381603-S36549337812010123000000) .
2. «REMOVE TRANSMISSION»(/bmw/m3/e90-2007-2013/remont/manual-trans/#manual-transmission-repair-e90) .

Convert shift rod joint.

Push back retaining ring (1) and drive out dowel pin (2).

Scheme 254

Note. Check damping disk (6) for damage and replace if necessary.

Scheme 255

Convert following parts from previous transmission to new transmission.

1. «RELEASE BEARING AND RELEASE LEVER»(/bmw/m3/e90-2007-2013/remont/clutches-manual-hydraulic/#clutch-repair-e90__21-51-500-removing-and-installing) .
2. Ball pin and spring wire clip
3. Studs for clutch slave cylinder
4. «PULSE GENERATOR, CRANKSHAFT/TRANSMISSION»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__13-62-610-replacing-pulse-generator)

Add final details to vehicle.

Check oil level.

Installation

Observe GREASING SPECIFICATION .

Scheme 256

0 General information Complete transmission, transmission oil change, transmission designations

1. Input shaft
2. Guide tube
3. Radial seal For drive shaft
4. Transmission temperature sensor
5. Transmission housing, front section
6. Transmission housing, rear section shafts, gear wheels, gearshift components
7. Radial seal For selector shaft
8. Shift shaft
9. Output shaft
10. Output flange
11. Radial seal For output flange
12. Reversing light switch
13. Zero-gear sensor
14. Speed sensor (transmission main shaft)
15. Crankshaft sensor

Notes

1. «CLAMP OFF BATTERY»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-00-instructions-for-disconnecting-and)
2. «MANUAL TRANSMISSION - OPERATING FLUIDS»(/bmw/m3/e90-2007-2013/remont/manual-trans/#manual-transmission-operating-fluids)
3. «REMOVE PROPELLER SHAFT»(/bmw/m3/e90-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft-repair-e90__26-11-000-removing-and-installing)
4. Remove «FRONT UNDERBODY PROTECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-490-removing-and-installingreplacing)

Disconnect plug connection (1) from reversing light switch.

Release cable from retainers.

Scheme 257

Disconnect plug connection (1).

Remove heat shield for crankshaft pulse generator.

Disconnect plug connection (2).

Release screws (3) and (4).

Scheme 258

Disconnect plug connection (1).

Unfasten screws (2).

Suspend holder (3) to one side.

Scheme 259

Release screws (1).

Tightening torque 23 00 1AZ .

Scheme 260

Disconnect plug connection (1).

Scheme 261

Disconnect plug connection (1).

Scheme 262

Note. Pressure line of clutch slave cylinder remains connected.

Scheme 263

Unscrew nuts.

Remove clutch slave cylinder.

Tightening torque 21 52 5AZ .

Supporting transmission

Support transmission with special tools 234050 and 002030.

Secure transmission to mounting with tensioning strap (1).

Tasks are described in 23... Universal BMW transmission take-up .

After completion of work, check transmission oil level.

Scheme 264

Remove CROSSMEMBER FOR TRANSMISSION MOUNTING (S65) .

Lever out retainer (1).

Clamp off shift rod (2).

Installation

Grease shift rod.

Grease, refer to MANUAL TRANSMISSION - OPERATING FLUIDS .

Make sure shims (3) are in correct position.

Scheme 265

Unlock bearing pin (1) in direction of arrow and remove.

Lift out shift arm.

Installation

Grease bearing pins (1).

Grease, refer to GEAR SHIFT MECHANISM - OPERATING FLUIDS .

Scheme 266

Lever support bearing (1) with a short screwdriver out of mounting.

Scheme 267

Installation

See GEAR SHIFT MECHANISM - OPERATING FLUIDS for greasing bearing pin of shift arm.

Fit support bearing (1) with opening (2) towards top rear onto holder.

Scheme 268

Bolt special tool 119990 with bolt (1) to front axle support.

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

Scheme 269

Adjust special tool 119990 until dimension A=50 mm is obtained between front axle support and tensioner.

Scheme 270

Disconnect plug connection (1) of zero gear sensor (on transmission).

Scheme 271

Release screws (1) and (2).

Tightening torque 23 00 1AZ .

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

Scheme 272

To avoid damaging the sound insulation (1) on the bulkhead, raise the transmission after withdrawing the transmission pin from the pilot bearing against the direction of engine lowering to 0°.

For safety, a protective film (2) can also be placed between the transmission and the sound insulation.

Scheme 273

Installation

Pay attention to correction position of dowel sleeves.

Replace damaged dowel sleeves.

Ensure correct position of cover plate.

Scheme 274

REMOVE RELEASE UNIT AND RELEASE LEVER and clean.

Check lubrication of transmission input shaft for sticky consistency. If grease is sticky, REPLACE CLUTCH PLATE .

Check clutch plate for friction rust in taper splines and REPLACE IF NECESSARY .

Mechanically remove old grease and lining abrasion from the taper splines of the clutch disk (with a cloth).

Scheme 275

Installation

Greasing specification

1. Remove release bearing and release lever.
2. Push on grease scraper ring «21 2 240»(/bmw/m3/e90-2007-2013/remont/clutches-manual-hydraulic/#clutch-special-tools-e90) as far as it will go.
3. Grease splines (1) of input shaft with a brush. Refer to «MANUAL TRANSMISSION - OPERATING FLUIDS»(/bmw/m3/e90-2007-2013/remont/manual-trans/#manual-transmission-operating-fluids) and «GEAR SHIFT MECHANISM - OPERATING FLUIDS»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#gear-shift-mechanism-operating-fluids) .
4. Detach grease scraper ring.

Scheme 276

Necessary preliminary work

1. Remove gearbox
2. Remove «CLUTCH RELEASE BEARING/LEVER»(/bmw/m3/e90-2007-2013/remont/clutches-manual-hydraulic/#clutch-repair-e90__21-51-500-removing-and-installing)

Drive a hole into the sealing cap (1) with a suitable tool (2).

Scheme 277

Screw special tool 230490 into sealing cap.

Withdraw sealing cap from transmission housing with aid of impact weight.

Scheme 278

Apply transmission oil to the sealing lip of the sealing cap (1) and insert.

Scheme 279

Drive sealing cap firmly home with special tool 230330.

Scheme 280

1. Remove underbody protection
2. Remove right heat shields.

Catch and dispose of gear oil with suitable equipment.

Observe country-specific waste-disposal regulations.

Unlock plug (1) and remove.

Release screw (2).

Remove speed sensor.

Scheme 281

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

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 BREAKDOWN DESIGNATION - TRANSMISSION

BMW BREAKDOWN DESIGNATION - SEQUENTIAL M GEARBOX

Manual gearbox

BMW BREAKDOWN DESIGNATION - MANUAL GEARBOX

Automatic transmission

BMW BREAKDOWN DESIGNATION - AUTOMATIC TRANSMISSION

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

Scheme 282

Support transmission with special tools 234050 and 002030.

Note. The transmission retaining bridge 240200 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 283

23 14 550 Removing/replacing zero gear sensor

1. Lower transmission

Tasks are described in Removing TRANSMISSION .

Disconnect plug connection (1) on zero gear sensor.

Unfasten screws (2).

Remove zero gear sensor.

Tightening torque 23 14 2AZ .

Scheme 284

23 11 614 Replacing guide tube for clutch release unit (GS6-53BZ) (S85/S65)

Note. (transmission removed)

1. Remove «CLUTCH RELEASE BEARING AND RELEASE LEVER»(/bmw/m3/e90-2007-2013/remont/clutches-manual-hydraulic/#clutch-repair-e90__21-51-500-removing-and-installing) from guide tube

Release screws.

Remove guide tube (1).

Clean thread.

Install screws with Loctite 243.

Tightening torque 23 11 2AZ .

Scheme 285

Note. Remove sticker (1) and adhesive with a suitable solvent.

Scheme 286

1. Remove rear underbody protection

GS6-17DG/BG and GS6-37DG/BG transmissions only.

Disconnect plug connection (1) on reverse gear switch.

Remove reverse gear switch.

Tightening torque 23 14 1AZ.

Note. Illustration similar

Scheme 287

GS6-53DG/BG transmission only

Disconnect plug connection (1) on reverse gear switch.

Remove reverse gear switch.

Tightening torque 23 14 1AZ.

Note. Illustration similar

Scheme 288

Necessary preliminary tasks

1. Remove «TRANSMISSION»(/bmw/m3/e90-2007-2013/remont/manual-trans/#manual-transmission-repair-e90) .
2. Remove «CLUTCH RELEASE UNIT AND RELEASE LEVER»(/bmw/m3/e90-2007-2013/remont/clutches-manual-hydraulic/#clutch-repair-e90__21-51-500-removing-and-installing) from guide tube.

Release screws.

Tightening torque: 23 11 2AZ .

Remove guide tube (1).

Installation

Clean guide tube.

Do not grease guide tube.

Drive a hole into radial shaft seal (1) using a center punch.

Screw in special tool 230490.

Drive out radial shaft seal (1) with impact weight (2).

Scheme 289

Installation

Coat sealing lips of radial seal with gear oil.

Push radial seal (1) onto drive shaft up to housing.

Drive in radial seal (1) as far as it will go with special tool 233240 and plastic hammer.

Scheme 290

Necessary preliminary tasks

1. Unflange propeller shaft from transmission and tie up to one side. Tasks are described in Removing propeller shaft.

Brace output flange with special tool 230020.

Release collar nut with special tool 232320.

Release E90, 91 M57T2, E60S85 with special tool 230200.

Installation

Mark flange with thermo pin and heat to min. 80°- 100°.

Scheme 291

Secure collar nut with Loctite 243.

1. Loctite 243: BMW Parts Service.
2. Tightening torque: «23 21 1AZ»(ref-381603-S30720459382010123000000) .

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

Scheme 292

Release screw on special tool 233210.

Slide special tool 233210 over output shaft and screw into sealing ring firmly.

Scheme 293

Insert screw into special tool 233210 again and continue turning until sealing ring is pulled out of transmission housing.

If necessary, remove ring spring of sealing ring.

Scheme 294

Installation

Coat sealing lips of new radial seal with gear oil.

Drive in radial seal as far as it will go with special tool 233230 and plastic hammer.

Scheme 295

Necessary preliminary tasks

1. Shift transmission into 2nd gear
2. Unflange propeller shaft from transmission.

Tasks are described in Removing propeller shaft.

Lever retaining ring (1) out of groove with a small screwdriver.

Slide locking ring (1) towards rear.

Drive out cylinder pin (2).

Scheme 296

Screw in special tool 230210 until it is firmly connected with radial seal (1).

Pull out radial seal with special tool 230210.

Scheme 297

Coat sealing lips of radial seal and selector shaft with transmission oil.

Drive in radial seal with special tool 230220.

Scheme 298

23 12 506 Replacing the drive shaft radial shaft seal (GS6-85BG)

Note. After completion of work, check gearbox oil level. Use only the approved gearbox oil. Failure to comply with this requirement will result in serious damage to the manual transmission!

Necessary preliminary work

1. Remove transmission.
2. Remove clutch release bearing.

Release bolts (1) and remove guide tube (2).

Scheme 299

Note. The shaft seal and the guide tube are replaced together.

Installation note

Wrap adhesive tape round keyway splines of drive shaft to avoid damaging the sealing ring while it is being installed.

Lubricate sealing lip of sealing ring.

Replace mounting bolts of guide bush.

Tightening torque, see 23 11 1AZ in 23 11 CASE AND COVER .

1. Lower transmission

Tasks are described in Removing TRANSMISSION .

Disconnect plug connection (1) on zero gear sensor.

Unfasten screws (2).

Remove zero gear sensor.

Tightening torque 23 14 2AZ .

1. Remove rear underbody protection

GS6-17DG/BG and GS6-37DG/BG transmissions only.

Disconnect plug connection (1) on reverse gear switch.

Remove reverse gear switch.

Tightening torque 23 14 1AZ.

Note. Illustration similar

GS6-53DG/BG transmission only

Disconnect plug connection (1) on reverse gear switch.

Remove reverse gear switch.

Tightening torque 23 14 1AZ.

Note. Illustration similar

1. Remove underbody protection
2. If necessary, remove left heat shields

Catch and dispose of gear oil with suitable equipment.

Observe country-specific waste-disposal regulations.

Unlock plug (1) and remove.

Remove oil temperature sensor (2).

Scheme 300

See also:
• MANUAL TRANSMISSION - OPERATING FLUIDS
• REAR UNDERBODY PROTECTION
• RELEASE BEARING AND RELEASE LEVER
• PULSE GENERATOR, CRANKSHAFT/TRANSMISSION
• CLAMP OFF BATTERY
• REMOVE PROPELLER SHAFT
• FRONT UNDERBODY PROTECTION
• 21 52 5AZ
• CROSSMEMBER FOR TRANSMISSION MOUNTING (S65)
• GEAR SHIFT MECHANISM - OPERATING FLUIDS
• REPLACE CLUTCH PLATE
• 21 2 240
• TRANSMISSION FLUID LEVEL
• TRANSMISSION FLUID LEVEL
• REMOVE TRANSMISSION
• DANGER OF POISONING
• RISK OF INJURY