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
- Headaches
- Dizziness
- Stomach aches
- Vomiting
- Diarrhoea
- Cramps/fits
- Unconsciousness
Protective measures/rules of conduct
- Pour oil only into appropriately marked containers
- Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
- Observe country-specific safety regulations
First aid measures
- 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
- Impaired sight
- Irritation of the eyes
- Reddening of the skin
- Rough and cracked skin
Protective measures/rules of conduct
- Wear protective goggles
- Wear oil-resistant protective gloves
- Observe country-specific safety regulations
First aid measures
- 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.
- 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
| WARNING | DANGER OF POISONING if oil is ingested/absorbed through the skin! RISK OF INJURY if oil comes into contact with eyes and skin! |
Recycling
Observe country-specific waste-disposal regulations.
Measures if oil is unintentionally released
- Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work area. Wear personal protective clothing/equipment.
- Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems, pits, cellars, water and the ground.
- Limiting spread: Use oil blocks to prevent the surface spread of oil.
- Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.
Note. Do not flush oil away with water or aqueous cleaning agents.
27 00... Replenishing / changing transfer box oil (ATC 450)
| IMPORTANT | Use only the approved oil in the transfer case. See TRANSFER CASE - OPERATING FLUIDS . Failure to comply with this requirement will result in serious damage to the transfer case! |
Note. Only change the oil when the transfer case is at normal operating temperature.
Necessary preliminary tasks
- Remove «TRANSMISSION CROSS MEMBER»(ref-349801-S20348991582009121000000) .
Checking/correcting transfer case oil level
Undo oil filler plug (1).
Check transfer case oil level.
If necessary, pour in oil up to lower edge of opening for oil filler plug (1).
Installation note
Tightening torque: 60 Nm
Replace oil filler plug (1).
Scheme 8
Changing transfer case oil
Remove exhaust system holder from transmission.
Tightening torque 18 20 1AZ.
Place oil collecting apparatus underneath.
Remove oil drain plug (1).
Drain and dispose of transmission oil.
Note. Observe country-specific waste-disposal regulations
Installation note
Replace oil drain plug (1).
Tightening torque: 60 Nm
Scheme 9
Undo oil filler plug (1).
Pour in oil up to lower edge of opening for oil filler plug (1).
Tightening torque: 60 Nm
Replace oil filler plug (1).
27 00... Replenishing/changing transfer case oil (ATC 700)
| IMPORTANT | Use only the approved oil in the transfer case. See TRANSFER CASE - OPERATING FLUIDS . Failure to comply with this requirement will result in serious damage to the transfer case! |
Note. Only change the oil when the transfer case is at normal operating temperature.
Necessary preliminary tasks
- Remove «UNDERBODY PROTECTION»(ref-351461-S01084639462009122100000) .
- If necessary, remove exhaust system
- Remove heat shields
Checking/correcting transfer case oil level
Undo oil filler plug (1).
Check transfer case oil level.
If necessary, pour in oil up to lower edge of opening for oil filler plug (1).
Installation
Tightening torque 27 00 11AZ , see 27 00 TRANSFER BOX IN GENERAL
Replace sealing ring.
Scheme 10
Changing transfer case oil
Place oil collecting apparatus underneath.
Remove oil drain plug (1).
Drain and dispose of oil.
Note. Observe country-specific waste-disposal regulations
Replace sealing ring, screw in oil drain plug (1) and tighten down.
Tightening torque 27 00 11AZ , see 27 00 TRANSFER BOX IN GENERAL
Scheme 11
Undo oil filler plug (1).
Pour in oil up to lower edge of opening for oil filler plug (1).
Tightening torque 27 00 11AZ , see 27 00 TRANSFER BOX IN GENERAL
Replace sealing ring.
27 10 010 Removing and installing transfer box ATC 700 (automatic transmission)
| IMPORTANT | After replacement, the "Repair" service function must be carried out with in the BMW diagnosis system. |
| WARNING | Danger to life! Mount securing fixture for vehicle on lifting platform to prevent the vehicle from slipping off or tilting down. |
| IMPORTANT | After completing work, check oil level and top up if necessary. |
Filler plug (1)
Tightening torque 27 00 11AZ , see 27 00 TRANSFER BOX IN GENERAL
Oil level up to filler edge of filler plug (1).
Use only approved oil. See TRANSFER CASE - OPERATING FLUIDS .
Failure to comply with this requirement will result in serious damage to the transfer box!
Necessary preliminary tasks
- Remove «UNDERBODY PROTECTION»(ref-351461-S01084639462009122100000) .
- Remove exhaust system bracket from transmission and transfer box
- Remove «PROPELLER SHAFT»(ref-349802-S38567150462009121000000) .
- Remove «FRONT PROPELLER SHAFT»(ref-349802-S15829197402010031100000) .
- Support transmission.
- Remove «TRANSMISSION CROSS-MEMBER»(ref-351449-S17419607782009122100000) .
Disconnect plugs (1) and (2) from servomotor.
Scheme 12
Release screw connection of transfer case.
Tightening torque 27 00 9AZ , see 27 00 TRANSFER BOX IN GENERAL
Remove transfer case.
Installation
Pay attention to dowel pin (1).
Grease dowel pin (1).
Apply a thin coat of grease to splines.
Grease: WEICON ANTI-SEIZE.
Scheme 13
27 10 010 Removing and installing transfer box (ATC 450)
| IMPORTANT | Before and after replacement, execute the "Repair" service function with the BMW diagnosis system. |
| IMPORTANT | After completing work, CHECK OIL LEVEL and top up if necessary. Failure to comply with this requirement will result in serious damage to the transfer box! |
Necessary preliminary tasks
- Disconnect «BATTERY EARTH LEAD»(ref-351441-S30936395632009122100000)
- Remove «UNDERBODY PROTECTION»(ref-351461-S01084639462009122100000) .
- Remove complete exhaust system
- Remove heat shields
- Remove «PROPELLER SHAFT»(ref-349802-S38567150462009121000000) .
- Remove «FRONT PROPELLER SHAFT»(ref-349802-S15829197402010031100000) .
Note. Support transmission with special tools 00 2 030, 23 4 050.
Scheme 14
Release screws.
Remove transmission cross member.
Tightening torques
Transmission cross member to body: 38 Nm
Transmission cross member to rubber mounts: 68 Nm
Scheme 15
Unplug connector (1) from VTG control unit (linear force module) (3).
Scheme 16
Release screw connection of transfer box.
Tightening torque: 43 Nm
Remove transfer box.
Installation note
Pay attention to dowel pin (1).
Grease dowel pin (1).
Apply a thin coat of grease to gearing.
Grease: WEICON ANTI-SEIZE.
Scheme 17
27 10 050 Replacing output flange for front axle output (ATC 450)
| IMPORTANT | Do not move vehicle with drive power once propeller shaft has been removed. Replace output flange only together with a new radial shaft seal. After completion of work, CHECK OIL LEVEL . Use only the approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . Failure to comply with this requirement will result in serious damage to the transfer box! |
Operation is identical to REPLACING RADIAL SHAFT SEAL FOR OUTPUT TO THE FRONT AXLE .
27 10 070 Replacing output flange on transfer box at rear (ATC450)
| IMPORTANT | After completing work, check OIL LEVEL and top up if necessary. Use only the approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . |
Note. Replace output flange only together with a new radial shaft seal. Operations for removing output flange are identical to replacing RADIAL SHAFT SEAL
Installation note
- Thickness of new shim must be determined before output flange is installed
Determine and note down dimension A of output flange (old and new).
Scheme 18
Determine and note down dimension B of output flange (old and new).
Scheme 19
Determine old dimension C, thickness of shim.
Scheme 20
Installation note
Calculate thickness of new shim
- Add old dimension A of output flange (previous) and old dimension C of shim Then subtract old dimension B from old result A+C
- Subtract dimension B from dimension A of output flange (new)
- Then subtract result of step 2 from result of step 1.
27 10 070 Replacing output flange on transfer box at rear (ATC700)
| IMPORTANT | After completing work, check oil level and top up if necessary. Use only the approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . |
Note. Operations for removing output flange are identical to replacing RADIAL SHAFT SEAL
Installation
- Thickness of new shim must be determined before output flange is installed
Determine and note down measurement A of output flange (previous and new).
Determine and note down measurement B of output flange (previous and new).
Determine measurement C, thickness of shim.
Installation
Calculate thickness of new shim
- Add measurement A of output flange (previous) and measurement C of shim (previous) Then subtract measurement B (previous) from result A+C (previous)
- Subtract measurement B from measurement A of output flange (new)
- Then subtract result of step 2 from result of step 1.
27 10 700 Removing and installing/replacing control unit for transfer box (ATC 700)
| IMPORTANT | Read and comply with notes on protection against electrostatic damage (ESD protection) . See 61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
- Replacement
Before and after replacement, execute the "Repair" service function with the BMW diagnosis system.
Necessary preliminary tasks
- Raise luggage compartment floor trim
Release screws (1).
Remove battery cover (2) towards top.
Scheme 21
Disconnect connector (1).
Unscrew nuts.
Remove control unit.
Scheme 22
27 10 710 Replacing classification resistor for servomotor (ATC 700)
| IMPORTANT | Delete previous resistance values when replacing the resistor. Using BMW diagnosis system, work through test program in accordance with instructions. |
Disconnect connector (1).
Release screw (2) and remove resistor.
Tightening torque 27 00 14AZ , see 27 00 TRANSFER BOX IN GENERAL
Scheme 23
27 10 720 Replacing servomotor (ATC 700)
| IMPORTANT | After replacement, the "Repair" service function must be carried out with in the BMW diagnosis system. |
Necessary preliminary tasks
- Remove «TRANSMISSION CROSS-MEMBER»(ref-351449-S17419607782009122100000) .
Disconnect plugs (1 and 2).
Tightening torque 27 00 14AZ , see 27 00 TRANSFER BOX IN GENERAL
Release screws and remove servomotor from transfer box.
Tightening torque 27 00 13AZ , see 27 00 TRANSFER BOX IN GENERAL
Scheme 24
27 21 010 Replacing radial shaft seal for drive flange (ATC 450)
| IMPORTANT | After completion of work, CHECK OIL LEVEL . Use only the approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . |
Necessary preliminary work
- Remove «TRANSFER BOX»(ref-351452-S04548549182013071500000) .
Drive a hole into radial shaft seal (1) using a center punch (2).
| IMPORTANT | Do not use a drill as metal shavings from drilling may result in transmission malfunction. |
Scheme 25
Screw special tool 23 0 490 (puller) into radial shaft seal.
Drive out radial shaft seal (1) with impact weight (2).
Scheme 26
Installation note
Coat sealing lips of new radial shaft seal with clean transmission oil.
Drive in radial shaft seal with special tool 27 1 430.
Scheme 27
Reassemble the vehicle.
Check OIL LEVEL .
Check transmission for leaks.
27 21 010 Replacing radial shaft seal for drive shaft (ATC 700)
Special tools required
- 23 0 490
- 27 1 460
See.
| IMPORTANT | After completing work, check oil level and top up if necessary. Use only approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . |
Necessary preliminary tasks
- Remove «transfer box»(ref-351452-S15369915302009122100000)
Drive a hole into radial shaft seal (1) using a center punch (2).
| IMPORTANT | Do not use a drill as metal shavings from drilling may result in transmission malfunction. |
Scheme 28
Screw in special tool 23 0 490 .
Drive out radial shaft seal (1) with impact weight (2).
Scheme 29
Drive in radial shaft seal with special tool 27 1 460 .
Scheme 30
Add final details to vehicle.
Check oil level.
Check transmission for leaks.
27 21 020 Replacing radial shaft seal for output flange (ATC 450)
| IMPORTANT | After completing work, check OIL LEVEL and top up if necessary. Use only approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . |
Necessary preliminary tasks
- Remove «PROPELLER SHAFT»(ref-349802-S38567150462009121000000) .
Release circlip (1).
Scheme 31
Release output flange with three-claw extractor tool.
Lever radial shaft seal out of housing with a suitable tool.
| IMPORTANT | Do not damage housing. |
Scheme 32
Installation note
Replace O-ring in output flange.
Check that O-ring is in correct position.
Scheme 33
Installation note
Coat sealing lips of new radial shaft seal with clean transmission oil.
Drive in radial shaft seal with special tool 27 1 440.
Scheme 34
Installation note
- Push on output flange
- Press down output flange using 2 screwdrivers
- Shim
- Continue pressing output flange down until retaining groove is completely visible
- Fit circlip
Scheme 35
27 21 020 Replacing radial shaft seal for output flange (ATC 700)
Special tools required
- 23 0 490
- 27 1 480
| IMPORTANT | After completing work, check oil level and top up if necessary. Use only approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . |
Necessary preliminary tasks
- Remove «PROPELLER SHAFT»(ref-349802-S38567150462009121000000) .
- Release exhaust system bracket
- Remove «TRANSMISSION CROSS-MEMBER»(ref-351449-S17419607782009122100000) .
Release retaining ring (1).
Installation
Replace O-ring in output flange.
Check that O-ring is in correct position.
| IMPORTANT | The propeller shaft may move when the output flange is pushed on. The retaining ring can thus no longer be fitted. |
Installation
- Push on output flange
- Using 2 screwdrivers, press output flange downwards or output shaft (2) upwards until groove for retaining ring is completely visible.
- Fit retaining ring.
Scheme 36
Drive a hole into radial shaft seal (1) using a center punch (2).
| IMPORTANT | Do not use a drill as metal shavings from drilling may result in transmission malfunction. |
Scheme 37
Screw in special tool 23 0 490 .
Drive out radial shaft seal (1) with impact weight (2).
Scheme 38
Drive in radial shaft seal with special tool 27 1 480 .
Scheme 39
Add final details to vehicle.
Check oil level.
Check transmission for leaks.
27 21 030 Replacing radial shaft seal for output to the front axle (ATC 450)
| IMPORTANT | After completing work, check OIL LEVEL and top up if necessary. Use only approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . |
Necessary preliminary tasks
- Remove «FRONT PROPELLER SHAFT»(ref-349802-S15829197402010031100000) .
Remove protective cap (1) with a screwdriver.
Scheme 40
Drive a hole into radial shaft seal (1) using a center punch (2).
| IMPORTANT | Do not use a drill as metal shavings from drilling may result in transmission malfunction. |
Scheme 41
Screw in special tool 23 0 490 (puller).
Drive out radial shaft seal (1) with impact weight (2).
Scheme 42
Drive in radial shaft seal with special tool 27 1 470.
Scheme 43
Reassemble the vehicle.
Check OIL LEVEL .
Check transmission for leaks.
27 21 040 Replacing radial shaft seal for actuator shaft (ATC 450)
| IMPORTANT | Read and comply with notes on protection against ELECTROSTATIC DISCHARGE (ESD PROTECTION) . |
Necessary preliminary tasks
- Disconnect «NEGATIVE BATTERY CABLE»(ref-351441-S30936395632009122100000)
- Remove «CROSS MEMBER»(ref-349801-S20348991582009121000000) .
Disconnect connector (1).
Release screws (2) and remove transfer box from control unit (longitudinal torque module) (3).
Tightening torque: 22 Nm
Thread special tool 23 0 490 (puller) into radial shaft seal (1).
Drive out radial shaft seal (1) with impact weight (2).
Push the assembly sleeve 11 1 380 (holding sleeve) over the actuator shaft.
| IMPORTANT | Non-observance involves a risk of damage to the radial shaft seal. |
Slide the new radial shaft seal (1) over the assembly sleeve (2) onto the actuator shaft.
Drive radial shaft seal fully home using special tool 11 1 200 and plastic hammer.
Remove the assembly sleeve.
27 21 030 Replacing radial shaft seal for front axle output (ATC 700)
Special tools required
- 23 0 490
- 27 1 470
| IMPORTANT | After completion of work, check transmission oil level . Use only the approved oil in this transfer box. See TRANSFER CASE - OPERATING FLUIDS . |
Necessary preliminary tasks
- Remove front «PROPELLER SHAFT»(ref-349802-S38567150462009121000000) .
Remove protective cap (1) with a screwdriver.
Scheme 44
Drive a hole into radial shaft seal (1) using a center punch (2).
| IMPORTANT | Do not use a drill as metal shavings from drilling may result in transmission malfunction. |
Scheme 45
Screw in special tool 23 0 490 .
Drive out radial shaft seal (1) with impact weight (2).
Scheme 46
Drive in radial shaft seal with special tool 27 1 470 .
Scheme 47
Add final details to vehicle.
Check oil level.
Check transmission for leaks.