On-Vehicle Servicing BMW Z4 E85/E86

APPLICATION

MANUAL TRANSMISSION APPLICATION

SERVICE INTERVALS

Inspect fluid level when vehicle is serviced. DO NOT drain fluid, transmission has lifetime fluid.

CHECKING FLUID LEVEL

Note. Numbers in text refer to numbers in figures.

Check lubricant at fill hole (2). For E60 vehicles (Scheme 42) For Z4 (Scheme 43) Lubricant should be at bottom of filler plug hole. Tighten Plug to specification. See TORQUE SPECIFICATIONS.

Scheme 42

Scheme 43

DRAINING/TOPPING UP GEAR OIL IN MANUAL TRANSMISSION

Note. Numbers in text refer to numbers in figures.

Note. Gearbox must be at normal operating temperature. For recommended fluid, see RECOMMENDED FLUID . For fluid capacity, see FLUID CAPACITIES .

Draining gear oil: release oil drain plug (1) and filler plug (2). For E60 vehicles (Scheme 42) For Z4 (Scheme 43) Clean oil drain plug (1), screw in and tighten to specification. See TORQUE SPECIFICATIONS. Fill transmission with gear oil. until overflowing. Screw in filler plug (2). Tighten to specification. See TORQUE SPECIFICATIONS.

RECOMMENDED FLUID

For model years 1998-2003, all manual transmissions are filled with Esso/Exxon MTF-LT-1 lifetime fluid. A Yellow label with the letters MTF-LT-1 is located next to the oil filler plug. Except for models specified under SERVICE INTERVALS , no oil change is required for the service life of the transmission.

From model year 2004, some manual transmissions are filled with Castrol MTF-LT-2 lifetime fluid. This fluid has the same properties as the MTF-LT-1 fluid. The MTF-LT-1 fluid may be mixed or substituted for the MTF-LT-2 manual transmission fluid.

FLUID CAPACITIES

Fluid capacity is approximately 1.4 qts. (1.3L). Transmission should be filled to bottom of filler plug hole.

GEARSHIFT LINKAGE

No external adjustment is necessary.

REPLACING RADIAL SEAL FOR OUTPUT FLANGE (S5D 200G / 250G)

Remove output flange. See Replacing Output Flange For Transmission (S5D 200G / 250G) .

Remove radial seal with Special Tool (00 5 010). (Scheme 44)

Scheme 44

Installation: coat sealing lips of new radial seal with transmission oil. Drive in radial seal with Special Tool (24 0 110) and plastic hammer until flush. (Scheme 45)

Scheme 45

REPLACING RADIAL SHAFT SEAL FOR OUTPUT FLANGE (GS6-37BZ/DZ H-TRANSMISSION

Remove exhaust system. See REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (M54) .

Preparing Special Tool (23 0 130): screw both Special Tools (23 0 134) onto Special Tools (23 0 131) and (23 0 132). (Scheme 46) Observe markings.

Scheme 46

Support transmission with Special Tools (00 2 030) and (23 0 130). (Scheme 47)

Scheme 47

Remove transmission cross-member (E60/E46/E87/E63/E64). (Scheme 48)

Scheme 48

Remove transmission bearing pedestal (E60/E53/E63/E64).

Unflange propeller shaft from transmission and tie up to one side. See REMOVING AND INSTALLING PROPELLER SHAFT (CARDAN UNIVERSAL JOINT) COMPLETELY .

Brace output flange with Special Tool (23 0 020). (Scheme 49) Release collar nut with Special Tool (23 2 320). Upon installation, mark flange with thermo pin and heat to min. 100°C. DO NOT drive on flange. Secure collar nut with Loctite 243. Tighten to specification. See TORQUE SPECIFICATIONS.

Scheme 49

Detach output flange with Special Tool (33 1 150) from output shaft. (Scheme 50)

Scheme 50

Release screw on Special Tool (23 3 161). Push special tool over output shaft and screw firmly into sealing ring. (Scheme 51)

Scheme 51

Insert screw into special tool again and continue turning until sealing ring is pulled out of transmission housing. (Scheme 52) If necessary, remove Woodruff key of sealing ring.

Scheme 52

Installation: coat sealing lips of new radial seal with gear oil. Drive in radial seal as far as it will go with Special Tool (23 3 162) and plastic hammer. (Scheme 53)

Scheme 53

Replacing Radial Seal For Selector Shaft (S5D 200G / 250G)

Note. Numbers in text refer to numbers in figures.

Shift transmission into 2nd gear. Unflange propeller shaft from transmission and tie back to one side. See REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT .

Lever retaining ring (1) out of groove with a small screwdriver. (Scheme 54) Push retaining ring (1) towards rear. Drive out straight pin (2).

Scheme 54

Screw in Special Tool (23 0 210) until it is firmly connected to radial seal (1). (Scheme 55) Pull out radial seal with Special Tool (23 0 210).

Scheme 55

Coat sealing lips of radial seal and selector shaft with gear oil. Drive in radial seal with Special Tool (23 0 220). (Scheme 56)

Scheme 56

Replacing Output Flange For Transmission (S5D 200G / 250G)

Unflange propeller shaft and tie up to one side. See REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT . If necessary, remove heat shields. Support transmission.

Release screws on cross-member. (Scheme 57) Lower transmission. Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.

Scheme 57

Brace output flange with Special Tool (23 0 020). (Scheme 58) Unfasten collar nut with Special Tool (23 1 210). Upon installation, insert collar nut with Loctite 243 screw securing adhesive and tighten to specification. See TORQUE SPECIFICATIONS.

Scheme 58

Detach output flange with Special Tool (33 1 150) from output shaft. (Scheme 59)

Scheme 59

REMOVING HYDRAULIC PUMP RELAY (SMG)

Note. Numbers in text refer to numbers in figures.

Release screws (1). (Scheme 60) Lift off electronics box cover.

Scheme 60

Unlock and detach relay (1). (Scheme 61)

Scheme 61

REPLACING EXPANSION TANK GS6S37BZ (SMG)

Note. Numbers in text refer to numbers in figures.

Note. After completing work: check fluid level in hydraulic system by means of DIS Tester "Service Function". Perform "Teach in transmission" service function by means of DIS Tester.

Remove assembly underside protection (E60 only).

Release nuts and remove heat shield (1). (Scheme 62) Upon installation, Tighten to specification. See TORQUE SPECIFICATIONS.

Scheme 62

Unscrew bolt (1). (Scheme 63) Upon installation, make sure retainer (2) for heat shield is correctly positioned. Tighten to specification. See TORQUE SPECIFICATIONS.

Scheme 63

Release stud bolt (1) and screw (2). (Scheme 64) Remove expansion tank in direction of arrow. Upon installation, replace both sealing rings. Grease sealing rings. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.

Scheme 64

REPLACING PRESSURE SENSOR GS6S37BZ (SMG)

Note. Numbers in text refer to numbers in figures.

Note. After completing work: check fluid level in hydraulic system by means of DIS Tester "Service Function". Perform "Teach in transmission" service function by means of DIS Tester.

Remove assembly underside protection (E60 only).

Release screws (1) and remove protective plate. (Scheme 65) Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.

Scheme 65

Disconnect plug and release pressure sensor (2). (Scheme 66) Upon installation, replace sealing ring. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.

Scheme 66

REPLACING SOLENOID VALVE EV3 FOR SELECTION ANGLE BRAKE GS6S37BZ (SMG)

Note. Numbers in text refer to numbers in figures.

Note. After completing work: check fluid level in hydraulic system by means of DIS Tester "Service Function". Perform "Teach in transmission" service function by means of DIS Tester.

Remove assembly underside protection (E60 only).

Release nuts and remove heat shield (1). (Scheme 62) Upon installation, tighten nuts to specification. See TORQUE SPECIFICATIONS.

Loosen screws (1). (Scheme 67) Release pressure accumulator (2) at hexagon head (3). Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS.

Scheme 67

Installation: replace sealing ring (1). (Scheme 68) Pay attention to installation position of sealing ring.

Scheme 68

Detach plug from solenoid valve EV3 (1). (Scheme 66)

Release screws (1) and pull solenoid valve out. (Scheme 69) Upon installation, replace sealing ring. Tighten screws to specification. See TORQUE SPECIFICATIONS.

Scheme 69

REPLACING PRESSURE ACCUMULATOR GS6S37BZ (SMG)

For procedure, see REPLACING SOLENOID VALVE EV3 FOR SELECTION ANGLE BRAKE GS6S37BZ (SMG) .

REPLACING A SOLENOID VALVE (CLUTCH OR GEARSHIFT) GS6S37BZ SMG

Note. Numbers in text refer to numbers in figures.

Note. After completing work: check fluid level in hydraulic system by means of DIS Tester "Service Function". Perform "Teach in transmission" service function by means of DIS Tester.

Procedure is identical for all solenoid valves: (1) Solenoid valve EV3, (2) Pressure sensor, (3) Solenoid valve EV2, (4) Solenoid valve EV1 and (5) Solenoid valve EV0. (Scheme 65)

Remove assembly underside protection (E60 only).

Release nuts and remove heat shield (1). (Scheme 62) Upon installation, tighten nuts to specification. See TORQUE SPECIFICATIONS.

Release screws (1) and remove protective plate. (Scheme 65) Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.

Release screws (2). (Scheme 70) Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.

Scheme 70

Remove screws (1) and (2). (Scheme 71) Lower valve block until screws of solenoid valve are accessible. Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.

Scheme 71

Detach plug from solenoid valve. Release screws (1) and pull solenoid valve out. (Scheme 72) Upon installation: replace sealing ring. Tighten screws to specification. See TORQUE SPECIFICATIONS.

Scheme 72

REPLACING VALVE BLOCK GS6S37BZ (SMG)

Note. Numbers in text refer to numbers in figures.

Note. After completing work: check fluid level in hydraulic system by means of DIS Tester "Service Function". Perform "Teach in transmission" service function by means of DIS Tester.

Procedure is identical for all solenoid valves: (1) Solenoid valve EV3, (2) Pressure sensor, (3) Solenoid valve EV2, (4) Solenoid valve EV1 and (5) Solenoid valve EV0. (Scheme 65)

Remove assembly underside protection (E60 only).

Release nuts and remove heat shield (1). (Scheme 62) Upon installation, tighten nuts to specification. See TORQUE SPECIFICATIONS.

Release screws (1) and remove protective plate. (Scheme 65) Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.

Loosen screws (1). (Scheme 67) Release pressure accumulator (2) at hexagon head (3). Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS.

Installation: replace sealing ring (1). (Scheme 68) Pay attention to installation position of sealing ring.

Release stud bolt (1). (Scheme 64) Lift out expansion tank in direction of arrow from valve block. Upon installation, tighten bolt to specification. See TORQUE SPECIFICATIONS.

Pull off plug (1). (Scheme 73)

Scheme 73

Unlock and disconnect lines (1) and (2). (Scheme 74)and (Scheme 75). Upon installation, replace sealing rings.

Scheme 74

Scheme 75

Remove screws (1) and (2). (Scheme 71) Remove valve block. Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS.

REPLACING HYDRAULIC PUMP GS6S37BZ (SMG)

Note. Numbers in text refer to numbers in figures.

Note. After completing work: check fluid level in hydraulic system by means of DIS Tester "Service Function". Perform "Teach in transmission" service function by means of DIS Tester.

Remove assembly underside protection (E60 only).

Release screw (1) and remove grounding strap. (Scheme 76)

Scheme 76

Release nuts and remove heat shield (1). (Scheme 62) Upon installation, tighten nuts to specification. See TORQUE SPECIFICATIONS.

Release line (1) and screws (2). (Scheme 77) Unlock connector and remove. Remove hydraulic pump. Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS.

Scheme 77

REPLACING CLUTCH ACTUATOR GS6S37BZ (SMG)

Note. After completing work: check fluid level in hydraulic system by means of DIS Tester "Service Function". Perform "Teach in transmission" service function by means of DIS Tester.

Note. Numbers in text refer to numbers in figures.

Remove assembly underside protection (E60 only).

Unlock connector and remove. Unlock and disconnect line (1). (Scheme 78) Release nuts (2) and remove clutch actuator (3). Upon installation, replace sealing ring. Tighten nuts to specification. See TORQUE SPECIFICATIONS.

Scheme 78

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• RECOMMENDED FLUID
• FLUID CAPACITIES
• SERVICE INTERVALS
• CHECKING FLUID LEVEL
• Replacing Output Flange For Transmission (S5D 200G / 250G)
• REPLACING SOLENOID VALVE EV3 FOR SELECTION ANGLE BRAKE GS6S37BZ (SMG)