APPLICATION
For transmission application, see AUTOMATIC TRANSMISSION APPLICATION table. For transmission application and oil recommendation (Scheme 244)- (Scheme 248). Also see LUBRICATION.
| Application | Transmission Model |
|---|---|
| 3-Series (E46) | A5S 325Z (5HP19), A5S 360R/390R (GM5) |
| 525i (E39) | A5S 325Z (5HP19) |
| 528i (E39) | A5S 360R/390R (GM5) |
| 530i (E39) | A5S 325Z (5HP19) |
| X3 (E83) | A5S 360R/390R (GM5) |
| X5 3.0L (E53) | A5S 360R/390R (GM5) |
| Z4 (E85) | A5S 325Z (5HP19) |
AUTOMATIC TRANSMISSION APPLICATION
Scheme 244
Scheme 245
Scheme 246
Scheme 247
Scheme 248
LUBRICATION
Note. Transmission is sealed at factory for life of transmission. If any leaks are found, factory recommends replacing transmission assembly.
SERVICE INTERVALS
Transmission fluid replacement is not necessary, except for some newer model vehicles with Condition Based Service. See AUTOMATIC TRANSMISSION overview article.
CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z)
| CAUTION | It is absolutely essential to use the approved automatic transmission fluid in this automatic transmission. Failure to comply with this requirement will result in serious damage to the automatic transmission. See RECOMMENDED FLUID . |
Note. Before releasing filler plug (1), make sure temperature of automatic transmission fluid is at least 30 °C.
Note. Numbers in text refer to numbers in figures.
Add ATF After Repairs
Selector lever to setting "P". The vehicle must be horizontal and should be secured to prevent it from rolling away. Connect BMW Diagnosis and Information System (DIS) or BMW MoDiC to car.
Release filler plug (1). (Scheme 249) Top up automatic transmission fluid until it flows over. Screw in filler plug (1) by hand. Start engine and run at idle speed. Operate brake and shift through all gears at idle speed several times (hold gears for 3 sec. in each case).
Scheme 249
Release filler plug (1) again. Top up automatic transmission fluid until it flows over. Increase temperature of automatic transmission fluid to 40-50°C. Check temperature of automatic transmission fluid with MoDiC or DIS. Screw in filler plug (1).
Installation: replace filler plug (1). Tighten to specification. See TORQUE SPECIFICATIONS .
Check Fluid Level
Connect BMW Diagnosis and Information System (DIS) and/or BMW MoDiC to vehicle and perform fluid level check in accordance with instructions.
CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R/390R, A4S 200R/310R)
Note. Numbers in text refer to numbers in figures.
| CAUTION | Use only the approved transmission fluid in this automatic transmission. See RECOMMENDED FLUID . Failure to comply with this requirement will result in serious damage to the automatic transmission. Refer also to adhesive label on transmission fluid sump. |
Move selector lever to park position "P". The vehicle must be horizontal and secured against rolling off.
Connect BMW Diagnosis and Information System (DIS) or BMW MoDiC to vehicle. Release filler plug (1). (Scheme 250) Top up automatic transmission fluid until overflowing. Screw in filler plug (1) by hand. Start engine and run at idle speed. Actuate brake and shift through all gears at idle speed. Open filler plug (1) again. Increase temperature of transmission fluid to 30-50°C. Interrogate temperature of transmission fluid with MoDiC or DIS. Top up automatic transmission fluid until overflowing. Screw in filler plug (1).
Scheme 250
Installation: check sealing ring on filler plug (1) for damage and, if necessary, replace sealing ring and filler plug. Tighten to specification. See TORQUE SPECIFICATIONS .
330xi (6/00 To Present)
The transmission oil pan will be labeled with either Texaco ETL-7045 or Dexron III. Fill or top off with the proper fluid only. Do not mix Texaco ETL-7045 and Dexron fluids.
330i & 330Ci (6/00 To Present) & 325i & 325Ci (9/00 To Present)
No fluid changes are necessary. Never mix any other oil with this transmission when doing repair or when topping off. Use ESSO (LT 711441) BMW part No. (83 22 9 407 807).
GEARSHIFT SELECTOR LEVER CABLE (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Check cable for ease of movement. More selector lever to "P" setting. Grip clamp bushing (1). Loosen nut (2). Press selector lever (3) forward (park position). Press cable (4) in direction of arrow and release again. Grip clamping piece (1). Tighten nut (2) to 88 INCH lbs. (10 N.m). (Scheme 251) Move selector lever to "P" position. Check whether parking lock is engaged by rotating shaft or pushing car.
Scheme 251
ADJUSTING SELECTOR LEVER (A5S 360R/390R, A4S 200R, 6HP26Z/19Z)
Note. Numbers in text refer to numbers in figures.
Check cable for ease of movement. Move selector lever to "P" position.
Grip clamping sleeve (1). (Scheme 252) Slacken nut (2). Press selector lever (3) forwards into park position. Press cable (4) in direction of arrow and release again. Grip clamping sleeve (1). Tighten down nut (2) to specification. See TORQUE SPECIFICATIONS.
Scheme 252
Installation: move selector lever to "P" position. Check whether parking gear is engaged by turning propeller shaft.
CONTROL UNIT
Turn off ignition. Connect MoDiC or DIS Tester. Turn on ignition. Select "Programming". For subsequent procedure, follow MoDiC or DIS instructions. Installation location of control unit, refer to DIS Tester.
REMOVAL & INSTALLATION
| CAUTION | It is absolutely essential to use the approved automatic transmission fluid in this automatic transmission. Failure to comply with this requirement will result in serious damage to the automatic transmission. |
REMOVING AND INSTALLING OR REPLACING PARKING LOCK (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove and install transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
Push in detent disk (1) in direction of arrow up to stop. (Scheme 253) Unfasten screws (2). Remove guide bracket (3). Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Scheme 253
Unscrew bolt (1). (Scheme 254) With an offset tool (2) (e.g. hexagon socket screw key 5 A/F), push out guide pin of locking pawl (4). Remove spring (3) and locking pawl (4). Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Scheme 254
Installation: check function of parking lock. Move selector lever into "P" setting. Check whether parking lock is engaged by rotating Cardan shaft or by pushing car.
REMOVING AND INSTALLING/REPLACING POSITION SWITCH (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Move selector lever into "P" setting. Unlock cable plug (1) and disconnect. (Scheme 255)
Scheme 255
Release screw. Remove cable plug (1) with retaining bracket. (Scheme 256)
Scheme 256
Grip clamping sleeve (1). (Scheme 257) Loosen nut (2). Installation: adjust selector lever. See GEARSHIFT SELECTOR LEVER CABLE.
Scheme 257
Grip cable at hexagon head (1). Unscrew nut (2). (Scheme 258) Remove cable from bracket. Upon installation, tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 258
Unscrew nut (1). (Scheme 259) Remove gearshift lever (2). Upon installation, tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 259
Unfasten screws. Detach position switch from manual shift valve shaft. (Scheme 260) Upon installation, pay attention to locating pin and cable routing.
Scheme 260
To install, reverse removal procedure.
REMOVING AND INSTALLING/REPLACING SHIFT UNIT (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove and install transmission sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
Remove and install/replace transmission fluid screen. See REMOVING AND INSTALLING/REPLACING TRANSMISSION OIL SCREEN (A5S 325Z) .
Remove retaining clip with screwdriver (2). (Scheme 261) Insert transmission plug (1) in transmission. Upon installation: to facilitate assembly, coat O-ring with Vaseline. (Scheme 262)
Scheme 261
Scheme 262
Release screws (1). (Scheme 263) Remove pulse generator (2). Pull off connector (3).
Scheme 263
Unfasten screws. (Scheme 264) Take off valve body. Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Scheme 264
Installation: coat O-rings (1) with automatic transmission fluid. (Scheme 265)
| CAUTION | Journal (1) of detent disk must be located in groove (2) of slide valve. (Scheme 266) |
Scheme 265
Scheme 266
REPLACING SOLENOID VALVE OR PRESSURE REGULATOR (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove and install transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
To locate solenoid valve and pressure regulator components (Scheme 267)
Scheme 267
Detach plug (1) from solenoid valve or pressure regulator. (Scheme 268)
Scheme 268
Release screws (1). (Scheme 269) Remove retaining plate (2). Withdraw solenoid valve (1, 2 or 3) or pressure regulator (2, 3 or 4). Upon installation: coat new solenoid valve with ATF.
Scheme 269
Installation: note installation position of retaining plate (2). (Scheme 270) Curved surface of retaining plate (2) must point to solenoid valve or pressure regulator. Install screws (1). Tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 270
REMOVING AND INSTALLING/REPLACING SELECTOR UNIT (A5S 360R/390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove and install transmission fluid sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION FLUID SUMP (A5S 360R / 390R, A4S 200R) .
Remove and install/replace transmission fluid screen. See REMOVING AND INSTALLING/REPLACING TRANSMISSION SCREEN (A5S 360R / 390R, A4S 200R) .
Note. As of model year 2001 (04/2000), the temperature sensor is integrated in the wiring harness.
Disconnect all plug connections on shift unit. (Scheme 271) Unclip temperature sensor (1) from holder.
Scheme 271
| NOTE |
DO NOT release screws (1). (Scheme 272) Release all other screws, with outside Torx E8, on shift unit and remove shift unit.
Scheme 272
Pull out seals (1), (2) and (3). (Scheme 273) Coat new seals with automatic transmission fluid and install.
Scheme 273
Installation: blow out tapped holes with compressed air gun. Insert set screws (1) from seal set into tapped holes. (Scheme 274)
Scheme 274
Length of screws: (1) = (2) = 68 mm, all others = 58 mm. Install shift unit with aid of both set screws and secure in place with screws. (Scheme 275) Remove both set screws. Tighten all screws until hand-tight. When tightening screws: follow sequence without fail. Tighten to specification. See TORQUE SPECIFICATIONS. Do not tighten screws (1) and (2) yet.
Scheme 275
Suspend guide (1) of transmission switch in detent spring (2). (Scheme 276) Journal (3) of detent disk must be located in groove (4) of slide valve.
Scheme 276
Insert feeler gauge (1) between detent spring (2) and detent disk (3) and set gap of 0.80 mm by moving detent spring (2). (Scheme 277) Tighten down screws (4). See TORQUE SPECIFICATIONS.
Scheme 277
REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION FLUID SUMP (A5S 360R / 390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Open drain plug (1). (Scheme 278) Drain off automatic transmission fluid. Unscrew all bolts. Remove oil sump (2). Detach gasket from oil sump (2). Clean sealing faces. Upon installation, replace sealing ring on drain plug. Tighten drain plug to specification. See TORQUE SPECIFICATIONS.
Scheme 278
| CAUTION | Tighten down screws, not in diagonal sequence but rather in order, one time to specified torque. |
Fit new gasket on oil sump. Clean magnets (1) and reinstall in oil sump. (Scheme 279) Install oil sump. Insert all screws until contact is made with screw head in each case. Tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 279
REMOVING AND INSTALLING/REPLACING TRANSMISSION OIL SCREEN (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove and install transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
Release screws (1). (Scheme 280) Pull transmission oil screen (2) towards bottom and remove.
Scheme 280
Installation: coat sealing ring with ATF. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
REMOVING AND INSTALLING/REPLACING TRANSMISSION SCREEN (A5S 360R / 390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION FLUID SUMP (A5S 360R / 390R, A4S 200R) .
Pull off transmission fluid screen (1) towards bottom and remove. (Scheme 281)
Scheme 281
If the sealing ring (1) has remained in the pump housing, it must be removed and the transmission fluid screen replaced. (Scheme 282)
Scheme 282
Installation: different transmission fluid screens are used in petrol/gasoline and diesel engines. Therefore check specified measurement A prior to installation. (Scheme 283) Measurement A: Gasoline engine
- M52TU = 38-40 mm
- M43TU = 29-31 mm
Diesel engine: M57 = 29-31 mm. Position (1): Two gaskets are fitted.
Scheme 283
REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
| CAUTION | It is absolutely essential to use the approved automatic transmission fluid in this automatic transmission. Failure to comply with this requirement will result in serious damage to the automatic transmission. |
Release drain plug (1). (Scheme 284) Drain automatic transmission fluid. Unscrew all bolts. Remove oil sump (2). Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Scheme 284
Remove gasket (1). (Scheme 285) Clean sealing surface (2). Upon installation, replace seal.
Scheme 285
| CAUTION | Using torque wrench, do not tighten screws diagonally but once one after the other. DO NOT tighten screws further. |
Clean magnets (1) and insert in oil sump again (2). (Scheme 286) Install oil sump (2). Insert all screws until contact is made with screw head in each case. Tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 286
REMOVING & INSTALLING TRANSMISSION EXTENSION (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Remove heat shield (1). (Scheme 287)
Scheme 287
Remove heat shield (1). (Scheme 288)
Scheme 288
Support transmission with Special Tool (00 2 030 / 24 5 301 / 24 5 304). (Scheme 289)
Scheme 289
Release screws and remove cross-member (1). (Scheme 290) Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.
Scheme 290
Unfasten screws. (Scheme 291) Upon installation, replace self-locking nuts. Tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 291
Grip propeller shaft and release nuts. (Scheme 292) Bend propeller shaft downwards at center mount (1), detach from transmission output flange and tie back to one side on underbody of vehicle. Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.
Scheme 292
Unfasten screws. (Scheme 293) Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.
Scheme 293
Remove transmission extension. Upon installation, install shim (1). Replace O-ring (2). (Scheme 294)
Scheme 294
To install, reverse removal procedure.
REMOVING AND INSTALLING OR REPLACING TRANSMISSION EXTENSION HOUSING (A5S 360R / 390R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove complete exhaust system.
Remove heat shields. (Scheme 287)and (Scheme 288).
Support transmission with special tools 00 2 030 / 24 5 301 / 24 5 305. (Scheme 289)
Release screws. Remove cross-member (1). (Scheme 290) Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.
Release screws. (Scheme 291) Upon installation, replace self-locking nuts. Tighten to specification. See TORQUE SPECIFICATIONS.
Grip propeller shaft and release nuts. (Scheme 292) Bend propeller shaft downwards at center bearing (1). Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody. Upon installation, tighten nuts to specification. See TORQUE SPECIFICATIONS.
Version 1 without spring washer: grip output flange (1) with Special Tool (23 0 020). (Scheme 295) Release hexagon nut. Detach output flange (1). Upon installation, replace sealing ring in output flange (1). Install hexagon nut with screw retaining compound. Tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 295
Version 2 with spring washer: release hexagon nut (1) on output flange (2). (Scheme 296) Upon installation, install hexagon nut with screw retaining compound and tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 296
Version 2 with spring washer: remove spring washer (1). (Scheme 297) Remove output flange (2). Upon installation: note installation direction of spring washer (1). Replace sealing ring in output flange (2).
Scheme 297
Withdraw radial seal (1) with Special Tool (00 5 010). (Scheme 298)
Scheme 298
Release screws on transmission extension housing (1). (Scheme 299) Carefully pull off transmission extension housing (1). Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.
Scheme 299
| CAUTION | Existing shim (2) remains fitted and is not recalculated. |
Replace gasket between transmission housing (1) and end cover. (Scheme 300)
Scheme 300
| CAUTION | If shim is lost: Calculate new shim. |
Calculate measurement between contact face (1) and parking gear (2) with Special Tool (00 2 550). (Scheme 301) Calculate the new shim with this measurement from the following figure. (Scheme 302)
Scheme 301
Scheme 302
Installation: coat sealing lips of new radial seal with automatic transmission fluid. Drive in radial seal with Special Tool (24 1 090) until flush. (Scheme 303)
Scheme 303
REPLACING BEARING ON TRANSMISSION EXTENSION (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
| CAUTION | After completion of work, check transmission oil level. Use only approved transmission fluid. Failure to comply with this instruction will result in serious damage to the transmission. End play must be checked and, if necessary, adjusted. See REPLACING OUTPUT FLANGE (A5S 325Z) . |
Remove output flange. See REMOVING & INSTALLING TRANSMISSION EXTENSION (A5S 325Z) .
Lift out circlip (1). (Scheme 304) Remove ball ring (2).
Scheme 304
Heat transmission extension in area of bearing race to approx. 80°C (hot air blower). (Scheme 305) Remove bearing race (3). Installation: install first ball ring (4), then bearing race.
Scheme 305
REPLACING OUTPUT FLANGE (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Remove output flange from mounting. See REPLACING RADIAL SEAL FOR OUTPUT FLANGE (A5S 325Z) . Installation: coat sealing lip of radial seal and sealing surface of output flange with ATF.
Installation: an end float of 0.15 - 0.35 mm is required between parking interlock gear and end face of output flange. End play is adjusted with shim (1). (Scheme 335) Replace sealing ring.
Note. Output flange must be free.
Determining thickness of shim: clamp transmission extension in a vise. Press output flange in direction of arrow. (Scheme 306)
Scheme 306
Determine distance (A) from shoulder to sealing surface and distance (B) from shoulder to end face of output flange. (Scheme 307) Example
- A = 10.00 mm
- B = 7.50 mm
Scheme 307
Remove shim from sprag wheel. Press sprag wheel inwards. Determine distance (E) from sealing surface on transmission housing to shoulder (1) on parking lock gear. (Scheme 308) Example: E = 4.00 mm.
Scheme 308
Note. Shims are available in 0.2 mm increments from 0.8 to 2.8 mm.
Calculate shim thickness
- A - B = C
- E - C - end play = shim thickness
- If necessary: round distance to an amount divisible by 2. Pay attention to distance for end play (0.15 - 0.35 mm) in so doing. Example: 10 - 7.5 = 2.5 4 - 2.5 - 0.25 = 1.15 3. 1.2
Install shim (example: 1.20 mm).
REPLACING OUTPUT FLANGE (A5S 360R / 390R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove complete exhaust system.
Remove heat shield (1). (Scheme 287)
Release screws. (Scheme 291) Upon installation: replace self-locking nuts and tighten to specification. See TORQUE SPECIFICATIONS.
Grip propeller shaft. Release nuts. (Scheme 292) Bend propeller shaft downwards at center bearing (1). Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody. Upon installation, tighten nuts to specification. See TORQUE SPECIFICATIONS.
Grip output flange (1) with Special Tool (23 0 020). (Scheme 309) Release hexagon nut. Detach output flange (1). Upon installation, install hexagon nut with screw retaining compound and tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 309
Installation: replace inner sealing ring (1) on output flange (2). (Scheme 310)
Scheme 310
| CAUTION | There are two different output flanges; DO NOT mix them up. |
Version 1 (without spring washer) Identifying features
- There is no spring washer fitted between the flange nut and output flange to secure the output flange (2) on the flange nut (1). (Scheme 311)
- When this output flange is replaced, the add-on kit detailed below must be retrofitted.
| CAUTION | Only the modified version (Version 2) is still available as a replacement. |
Scheme 311
For retrofit kit (Scheme 312) Install add-on kit for output flange.
Scheme 312
| CAUTION | If the version 2 output flange is replaced by a version 2 model, the snap ring supplied in the add-on kit must not be replaced because the fitted snap ring is difficult to remove. (Scheme 312)The fitted snap ring must be left in the transmission |
Note. In series production, the output flange with spring washer is fitted from transmission serial number 7912 and has no color marking.
Version 2 (with spring washer) Identifying features
- As the substitute, the output flange with spring washer (2) is identified with a white marking (1) around its circumference. (Scheme 313)
- The spring washer (1) is fitted between flange nut and output flange (2). (Scheme 314)
Scheme 313
Scheme 314
REPLACING PRESSURE REGULATOR FOR CONVERTER LOCKUP CLUTCH (AS5 360R / 390R, A4S 200R)
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove shift unit. See REMOVING AND INSTALLING/REPLACING SELECTOR UNIT (A5S 360R / 390R, A4S 200R) .
Remove retaining spring. Pull out pressure regulator (1) for converter lockup clutch. (Scheme 315)
Scheme 315
Installation: coat new pressure regulator (1) for converter lockup clutch with automatic transmission fluid.
REPLACING PRESSURE REGULATOR FOR MAIN PRESSURE (A5S 360R/390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove transmission sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION FLUID SUMP (A5S 360R / 390R, A4S 200R) .
Remove transmission fluid screen. See REMOVING AND INSTALLING/REPLACING TRANSMISSION SCREEN (A5S 360R / 390R, A4S 200R) .
Disconnect plug (1) from pressure regulator (2) for main pressure. (Scheme 316) Remove retaining spring (3). Remove pressure regulator (2) for main pressure. Upon installation: coat new pressure regulator (2) for main pressure with automatic transmission fluid.
Scheme 316
REPLACING PRESSURE REGULATOR FOR SYSTEM PRESSURE (AS5 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove and install shift unit. See REMOVING AND INSTALLING/REPLACING SHIFT UNIT (A5S 325Z) .
Disconnect plug (1) from pressure regulator (2) for system pressure. (Scheme 317)
Scheme 317
Unscrew bolt (1). (Scheme 318) Remove retaining plate (2). Remove pressure regulator (3) for system pressure. Upon installation: coat new pressure regulator (3) for system pressure with ATF.
Scheme 318
Slide in pressure regulator (4). (Scheme 319) Install retaining plate (1) with lug (2) as illustrated. Install screw (3). Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
Scheme 319
REPLACING PULSE GENERATOR (OUTPUT SPEED) (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove and install transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
Unscrew bolt (1). (Scheme 320) Remove pulse generator (2). Upon installation, tighten bolt to specification. See TORQUE SPECIFICATIONS.
Scheme 320
Detach plug (1) from pulse generator (2). (Scheme 321)
Scheme 321
REPLACING PULSE GENERATOR (OUTPUT SPEED) (A5S 360R / 390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
Pull off plug (1). (Scheme 322) Unscrew bolt (2). Withdraw pulse generator (3). Upon installation, tighten bolt to specification. See TORQUE SPECIFICATIONS. Read out fault memory of EGS control unit. Check stored fault messages, eliminate faults and then clear fault memory.
Scheme 322
REPLACING PULSE GENERATOR (TURBINE SPEED) (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove and install transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
Remove and install transmission oil screen. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
Remove and install shift unit. See REMOVING AND INSTALLING/REPLACING SHIFT UNIT (A5S 325Z) .
Unscrew bolt (1). (Scheme 323) Withdraw pulse generator (2). Pull off connector (3). Upon installation, tighten bolt to specification. See TORQUE SPECIFICATIONS.
Scheme 323
REPLACING PULSE GENERATOR (TURBINE SPEED) (A5S 360R / 390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION FLUID SUMP (A5S 360R / 390R, A4S 200R) .
Pull off plug (1). (Scheme 324) Release screw (2). Withdraw pulse generator (3). Upon installation, tighten screw to specification. See TORQUE SPECIFICATIONS. Read out fault memory of EGS control unit. Check stored fault messages, eliminate faults and then clear fault memory.
Scheme 324
REPLACING RADIAL SEAL ON MANUAL SHIFT VALVE SHAFT (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove position switch from the manual shift valve shaft. See REMOVING AND INSTALLING/REPLACING POSITION SWITCH (A5S 325Z) .
Remove radial seal with Special Tool (24 5 260) from transmission housing. (Scheme 325)
Scheme 325
Installation: fit Special Tool (24 5 490) to the manual shift valve shaft. (Scheme 326) Coat sealing lip of new radial seal (1) with transmission oil. Slide radial seal onto manual shift valve shaft.
Scheme 326
Installation: press radial seal into transmission case with Special Tool (24 5 250). (Scheme 327) Pull Special Tool (24 5 490) off manual shift valve shaft.
Scheme 327
REPLACING RADIAL SHAFT SEAL FOR MANUAL SHIFT VALVE SHAFT (A5S 360R / 390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Grip clamping sleeve (1). Loosen nut (2). (Scheme 342) Upon installation, tighten nut to specification. See TORQUE SPECIFICATIONS.
Unscrew nut (1). Remove selector lever (2). (Scheme 343) Upon installation, tighten nut to specification. See TORQUE SPECIFICATIONS.
Screw Special Tool (24 5 361) into radial shaft seal. (Scheme 328)
Scheme 328
Screw Special Tool (24 5 362) onto Special Tool (24 5 361) and tighten down. (Scheme 329) This pulls the radial shaft seal out of the transmission housing.
Scheme 329
Screw adapter sleeve (1) from seal set onto manual shift valve shaft. (Scheme 330) Moisten sealing lips of radial shaft seal (2) with automatic transmission fluid. Push radial shaft seal (2) onto manual shift valve shaft. Press radial shaft seal (2) as far as possible into transmission housing. Grip radial shaft seal (2) firmly. Unscrew adapter sleeve (1) from manual shift valve shaft.
Scheme 330
Pull radial shaft seal into transmission housing up to stop with Special Tools (24 5 363) and (24 5 364). (Scheme 331) Upon installation, adjust selector lever. See ADJUSTING SELECTOR LEVER (A5S 360R / 390R, A4S 200R, 6HP26Z/19Z).
Scheme 331
E46 4WD: Selector Shaft Sealing Cap On Left Transmission Side Leaking
Lever out sealing cap (1) with a screwdriver (2). (Scheme 332)
Scheme 332
Note. Drift (2) for driving in sealing cap is contained in repair kit.
Place new sealing cap (1) on drift (2). (Scheme 333)
Scheme 333
Drive in new sealing cap (1) with drift (2) as far as it will go. (Scheme 334)
Scheme 334
REPLACING RADIAL SEAL FOR OUTPUT FLANGE (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Remove transmission extension. See REMOVING & INSTALLING TRANSMISSION EXTENSION (A5S 325Z) .
Clamp Special Tool (24 1 220) in vise. Fit transmission extension to the special tool. (Scheme 335)
Scheme 335
Knock back cotter pin in grooved nut. (Scheme 336) Upon installation, peen grooved nut to secure.
Scheme 336
Unfasten grooved nut (1) with Special Tool (24 1 170). (Scheme 337) Upon installation, tighten to specification. See TORQUE SPECIFICATIONS.
Scheme 337
Remove transmission extension from special tool. Remove output flange from mounting. (Scheme 338) Installation: coat sealing lip of radial seal and sealing surface of output flange with transmission oil.
Scheme 338
Lift out radial seal (1). (Scheme 339)
Scheme 339
Installation: drive in new radial seal (1) flush using Special Tool (00 5 500 / 24 1 190). (Scheme 340)
Scheme 340
REPLACING RADIAL SEAL FOR OUTPUT FLANGE (A5S 360R / 390R)
To replace radial seal for output flange, see REMOVING AND INSTALLING OR REPLACING TRANSMISSION EXTENSION HOUSING (A5S 360R / 390R) .
REPLACING SOLENOID VALVE 1, 2 OR 3 (A5S 360R / 390R, A4S 200R)
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION FLUID SUMP (A5S 360R / 390R, A4S 200R) .
| CAUTION | Note position of wiring harness. |
Disconnect plug from solenoid valve. Remove retaining spring and withdraw solenoid valve (1, 2 or 3). (Scheme 341) Upon installation: coat new solenoid valve with automatic transmission fluid.
Scheme 341
REPLACING TRANSMISSION SWITCH (A5S 360R / 390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Move selector lever to position "D". Remove transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION FLUID SUMP (A5S 360R / 390R, A4S 200R) .
Remove and install selector unit. See REMOVING AND INSTALLING/REPLACING SELECTOR UNIT (A5S 360R / 390R, A4S 200R) .
Grip clamping sleeve (1). Slacken nut (2). (Scheme 342)
Scheme 342
Release nut (1). (Scheme 343) Remove selector lever (2). Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust selector lever. See ADJUSTING SELECTOR LEVER (A5S 360R / 390R, A4S 200R, 6HP26Z/19Z).
Scheme 343
Drive spring pin (1) out of transmission switch (2). (Scheme 344) Withdraw manual shift valve shaft (3) from transmission only so far that transmission switch (2) can be removed. DO NOT remove parking gear rack. DO NOT move parking gear rack more than 10 mm; if necessary, secure with pointed pliers. Release notched disk on parking gear rack. Remove transmission switch (2) with detent disk.
Scheme 344
Remove transmission switch (1) from detent disk (2). (Scheme 345) Upon installation: bore holes for spring pin in transmission switch (1) must overlap with bore holes of detent disk (2) and manual shift valve shaft.
Scheme 345
Installation: attach parking gear rack (1) from rear in detent disk (2). (Scheme 346) Slide in manual shift valve shaft. Drive in spring pin. During entire installation work, journal (3) must be aligned vertically to manual shift valve shaft. After installation of detent spring, ensure that parking lock functions correctly. Press journal (3) forwards into "P" position, rotate propeller shaft and check that locking pawl engages.
Scheme 346
REPLACING WIRING HARNESS IN AUTOMATIC TRANSMISSION (A5S 325Z)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z) .
Remove and install transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z) .
Remove and install transmission oil screen. See REMOVING AND INSTALLING/REPLACING TRANSMISSION OIL SCREEN (A5S 325Z) .
Remove and install shift unit. See REMOVING AND INSTALLING/REPLACING SHIFT UNIT (A5S 325Z) .
Disconnect plug (1) from solenoid valve. (Scheme 347) Detach plug (2) from pulse generator (3).
Scheme 347
Remove connector (1). (Scheme 348) Remove retaining clip (2). Remove wiring harness from cable guide (3).
Scheme 348
REPLACING WIRING HARNESS IN AUTOMATIC TRANSMISSION (A5S 360R/390R, A4S 200R)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, top up ATF level. Check/top up fluid level in automatic transmission. See CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 360R / 390R, A4S 200R / 310R) .
Remove transmission oil sump. See REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION FLUID SUMP (A5S 360R / 390R, A4S 200R) .
Remove transmission plug at rear right.
Pull off transmission fluid screen (1) towards bottom and remove. (Scheme 281)
Note. If the sealing ring (1) has remained in the pump housing, it must be removed and the transmission fluid screen replaced. (Scheme 282)
Disconnect all plug connections on shift unit. Unclip temperature sensor (1) from holder. (Scheme 271)
Note. As of model year 2001 (04/2000), the temperature sensor is integrated in the wiring harness.
Remove retaining clip with screwdriver (2). (Scheme 261) Insert transmission plug (1) in transmission. Remove wiring harness from automatic transmission.
Installation: to facilitate installation, coat sealing rings with petroleum jelly. (Scheme 262) Make sure transmission plug is in correct position.
TORQUE SPECIFICATIONS
| Application | Ft. Lbs. (N.m) | |
|---|---|---|
| Bowden Cable On Shift Tower/Transmission | 11 (15) | |
| Center Mount-To-Body | 15 (21) | |
| Cross Member-To-Body | 15 (21) | |
| Flange Nut, Output Flange Without Spring Washer | 22 (30) | |
| Flange Nut, Output Flange With Spring Washer | 44 (60) | |
| Flexible Disk-To-Propeller Shaft & Transmission Output Flange | ||
| M10 8.8 Thread | 35 (48) | |
| M10 10.9 Thread | 47 (64) | |
| M14 Thread | 103 (140) | |
| M12 10.9 Thread | 74 (100) | |
| Flexible Disk-To-Transmission Output Flange (Screw With Rolled-On Shim Only) | ||
| Stage 1 | 37 (50) | |
| Stage 2 | Additional 90° | |
| Oil Filler Plug | ||
| A5S 360R | 13 (18) | |
| A5S 325Z | 22 (30) | |
| Oil Drain Plug (A5S 325Z) | 26 (35) | |
| Plug | 15 (20) | |
| Rubber Mounts-To-Cross Member Or Transmission | 15 (21) | |
| Slotted Nut/Output Flange | 89 (120) | |
| Transmission Extension | ||
| A5S 325Z | 18 (25) | |
| A5S 360R | 16 (22) | |
| INCH Lbs. (N.m) | ||
| Clamping Screw On Shift Lever | 89 (10) | |
| Guide Plate/Parking Lock Mechanism | 89 (10) | |
| Oil Strainer | 53 (6) | |
| Pulse Generator, Output Speed | 53 (6) | |
| Pulse Generator, Turbine Speed | 71 (8) | |
| Pulse Sender | 97 (11) | |
| Retaining Plate For Solenoid Valves & Pressure Regulator On Shift Unit | 53 (6) | |
| Selector Lever On Transmission | 89 (10) | |
| Transmission Oil Sump | ||
| A5S 325Z | 53 (6) | |
| A5S 360R | 89 (10) | |
| Valve Body-To-Transmission | ||
| A5S 325Z | 71 (8) | |
| A5S 360R | 97 (11) | |
TORQUE SPECIFICATIONS
See also:
• AUTOMATIC TRANSMISSION
• AUTOMATIC TRANSMISSION APPLICATION
• LUBRICATION
• TORQUE SPECIFICATIONS
• CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (A5S 325Z)
• REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION OIL SUMP (A5S 325Z)
• GEARSHIFT SELECTOR LEVER CABLE
• REMOVING AND INSTALLING/REPLACING TRANSMISSION OIL SCREEN (A5S 325Z)
• REMOVING AND INSTALLING/REPLACING TRANSMISSION SCREEN (A5S 360R / 390R, A4S 200R)
• REPLACING OUTPUT FLANGE (A5S 325Z)
• REMOVING & INSTALLING TRANSMISSION EXTENSION (A5S 325Z)
• REPLACING RADIAL SEAL FOR OUTPUT FLANGE (A5S 325Z)
• REMOVING AND INSTALLING/REPLACING SELECTOR UNIT (A5S 360R / 390R, A4S 200R)
• REMOVING AND INSTALLING/REPLACING SHIFT UNIT (A5S 325Z)
• REMOVING AND INSTALLING/REPLACING POSITION SWITCH (A5S 325Z)
• ADJUSTING SELECTOR LEVER (A5S 360R / 390R, A4S 200R, 6HP26Z/19Z)
• REMOVING AND INSTALLING OR REPLACING TRANSMISSION EXTENSION HOUSING (A5S 360R / 390R)