28 00... Checking/topping up oil level in twin-clutch gearbox (GS7D36SG)
Checking oil level
- Call up Service functions (Drive) in BMW diagnosis system
- Carry out oil level check in accordance with instructions
| IMPORTANT | On the twin-clutch gearbox a run-in check fluid change is not required at 2000 km. Use only the approved gear oil for dual clutch transmission GS7D36SG DCTF-1 Pentosin (P/N 83 22 2 147 477). . Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | The testing and filling procedure must be completed before the transmission oil temperature of 40°C is reached. If a temperature in excess of 40°C is reached and no oil has emerged, insert the fluid adjusting screw and repeat the testing and filling procedure when it has cooled down. |
Installation note
Tighten down filler plug using
- Hexagon wrench 8 A/F
- Torque wrench
- Socket 8 A/F
Scheme 100
Topping up transmission oil after a repair
Stand vehicle on a level surface and secure against rolling off.
Scheme 101
- Open fluid adjusting screw (1). If oil emerges, close screw again immediately If no oil emerges, top up until oil emerges and close oil adjusting screw (1) again NOTE: If oil has been replenished here, a further refill must be carried out during the actual oil adjustment.
- Connect diagnosis system and start service functions (drive).
- Start engine (drive position N or P)
- Record transmission temperature using Tester.
- (Drive position P)
- Permissible starting temperature < or = 32°C
- Idle speed: maintain at approx. 2000 RPM for 1 minute.
- Open the oil adjusting screw (1)
- Fill until oil emerges. Max. transmission oil temperature 40 degrees Celsius
- Insert screw.
Installation note
Replace screw.
28 00 101 Installing replacement transmission (GS7D36SG)
Drain gear oil at oil drain plug.
| IMPORTANT | After completion of work, program transmission control unit. |
Recycling
Catch and dispose of escaping transmission fluid.
Observe country-specific waste disposal regulations
| IMPORTANT | In case of twin-clutch gearbox N54, N55, before installing exchange transmission, always flush TRANSMISSION OIL COOLER TOGETHER WITH LINES . After completion of work, check oil level . . Replacement transmission is supplied filled with transmission fluid. Use only the approved gear oil for dual clutch transmission GS7D36SG DCTF-1 Pentosin (P/N 83 22 2 147 477). . Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
Necessary preliminary tasks
- Remove twin-clutch gearbox.
Note. Release screws. Remove and convert transmission bearing block (1).
Scheme 102
Picture shows N54.
Modify all transportation retainers.
Convert all cable clips.
Convert all seal plugs.
Convert protective cap on input shaft.
Transmission identification
- refer to BMW Parts Department.
- On type plate
Scheme 103
00..... Instructions for performing service functions on the twin-clutch gearbox (GS7D36SG)
Note. The service functions must be carried out in the relevant order!
| Replacement of clutch and after all work on opened transmission | Carry out fluid adjustment Teach in valve characteristic curves Teach in kiss point Parking lock hook test |
|---|---|
| Replacement of oil pump | Carry out fluid adjustment Teach in valve characteristic curves Teach in kiss point Parking lock hook test |
| Replacement of transmission (complete) | Read out transmission data before replacement Parking lock hook test Write transmission data Carry out fluid adjustment |
| Replacement/repair of parking lock cable, selector lever with parking lock unit | Parking lock hook test |
| Replacement of combination sensor | Carry out fluid adjustment Teach in valve characteristic curves Teach in kiss point Parking lock hook test |
| Opening/replacement of fluid adjustment screw, repair/replacement of transmission fluid cooler, oil cooler lines, thermostat, water/oil heat exchanger (M3) and seals | Carry out fluid adjustment |
TWIN-CLUTCH GEARBOX SERVICE FUNCTIONS CHART
Scheme 104
28 02 020 Removing and installing or replacing transmission oil sump (GS7D36SG)
| IMPORTANT | Remove transmission oil sump only after it has cooled down. It is essential to adhere to conditions of absolute cleanliness. Any dirty parts must be cleaned before the hydraulic cap is loosened. After completion of work, check oil level . . Use only the DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
Recycling
Catch and dispose of escaping transmission oil.
Observe country-specific waste disposal regulations.
Necessary preliminary work
- Remove rear underbody protection.
Remove oil drain plug (1).
Tightening torque, see 28 00 3AZ in 28 00 DOUBLE CLUTCH GEARBOX .
Drain off transmission oil.
Scheme 105
Unscrew all bolts.
Remove transmission oil sump (1).
Installation note
Clean sealing ring groove with fluff-free cloth.
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 .
Scheme 106
28 00 001 Removing and installing twin-clutch gearbox (GS7D36SG) N54
| IMPORTANT | Before the gearbox is removed, it is imperative that a read-out is taken of the specific gearbox data status. After completion of work, check oil level .. Use only the approved DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this requirement will result in serious damage to the twin-clutch gearbox! Apply a thin coating of "MI_Setral- 43N" grease to transmission input shaft! |
| IMPORTANT | Aluminum screws/bolts must be replaced each time they are released. Aluminum screws/bolts are permitted with and without color coding (blue). For reliable identification: Aluminum screws/bolts are not magnetic. Jointing torque and angle of rotation must be observed without fail (risk of damage). |
Necessary preliminary work
- Read out transmission data of the gearbox to be replaced with the BMW diagnosis system
- Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .
- Remove underbody protection at front and rear. See «51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION»(ref-381258-S36346312162010122800000) .
- Remove complete «EXHAUST SYSTEM»(/bmw/z4/e89-2009-2013/remont/exhaust/#exhaust-system-repair-n54) .
- Support engine with lifter when removing transmission.
Release screws (1).
Remove exhaust bracket (2).
Remove bracket (3).
Scheme 107
Disconnect connectors (1) and release leads.
Unfasten screws (2).
Remove cover plate (4).
Release aluminum bolt (3) on right next to cable retaining plate.
Aluminum screws must be replaced.
Tightening torque, see 28 00 1AZ in 28 00 DOUBLE CLUTCH GEARBOX .
Scheme 108
Release screw (1).
Unlock retainer (2).
Release cable from lever and holder.
Scheme 109
Supporting transmission
Support transmission with special tools 23 4 050 .
Secure transmission to mounting with tensioning strap (1).
Torque is in TRANSMISSION HOLDER .
After completion of work, check oil level .
Scheme 110
Unfasten screws (1) and nuts (2).
Remove transmission cross-member.
Tightening torque 22 32 3AZ/4AZ .
Scheme 111
Remove PROPELLER SHAFT .
Release screw (1).
Disconnect hydraulic lines (2) to transmission oil cooler.
Seal off pipes and connection holes on gearbox with plugs.
Installation note
Replace sealing rings.
Scheme 112
Release nut (1) and bracket from transmission oil lines on oil sump.
Scheme 113
- Lower transmission
- Unlock central transmission plug (1) by turning and disconnect.
- Do not touch pins.
- Release cable from retainers.
Operations are described in
Notes on mechatronics
| IMPORTANT | Read and comply with important note. |
Scheme 114
Installation note
Pay attention to routing and length of wiring harness.
Insert special tool 24 2 390 in sealing cup (1).
Scheme 115
Release screws.
Installation note
Observe screw fastening sequence without fail.
Tightening torque, see 28 00 1AZ in 28 00 DOUBLE CLUTCH GEARBOX .
Aluminum screws must be replaced.
Tightening torque and angle of rotation, aluminum screws (7.8.9.10.11), see 28 00 1AZ in 28 00 DOUBLE CLUTCH GEARBOX
Scheme 116
Installation note
Tighten down screws/bolts to specified torque.
Special angle-of-rotation tool 00 9 120 with 00 9 130 MAGNET
Secure to floor plate and screw down aluminum screws/bolts in accordance with angle of rotation.
Angle of rotation, see 28 00 1AZ in 28 00 DOUBLE CLUTCH GEARBOX .
Scheme 117
Installation note
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
Check that fitting sleeves are correctly fitted.
Replace damaged fitting sleeves.
Scheme 118
28 00 060 Replacing output flange radial shaft seal (GS7D36SG)
| IMPORTANT | It is essential to adhere to conditions of absolute cleanliness. Any dirty parts must be cleaned before the hydraulic cap is loosened. After completion of work, check oil level .. Use only the approved transmission oil DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
Necessary preliminary work
- Remove underbody protection. See «REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION»(ref-381258-S36346312162010122800000)
- Remove heat shields.
- Remove «EXHAUST SYSTEM»(/bmw/z4/e89-2009-2013/remont/exhaust/#exhaust-system-repair-n54__18-00-020-removing-and-installing) .
- Support transmission from underneath. See «23... UNIVERSAL BMW TRANSMISSION TAKE-UP»(/bmw/z4/e89-2009-2013/remont/manual-trans/#manual-transmission-repair-n54__23-universal-bmw-transmission-take-up) .
- Remove transmission cross member.
- Remove propeller shaft.
- Tasks are described in «PROPELLER SHAFT»(/bmw/z4/e89-2009-2013/remont/driveshaft-universal-joints/#propeller-shaft-repair-n54__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 .
Release nut with special tool 23 2 320 .
Tightening torque, see 28 10 14AZ in 28 10 HOUSING WITH ADD-ON PARTS .
Installation note
Replace nut and secure with Loctite 243.
Scheme 119
Detach output flange (1) with special tool 331 150 DEVICE and adapter plate 33 1 154 from output shaft.
Scheme 120
Attach special tool 24 2 353 to output shaft (1).
Graphic shows: Automatic transmission
Scheme 121
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 122
Apply oil to the sealing lip of radial shaft seal (1). Drive in radial shaft seal (1) with special tool 23 0 410 as far as it will go.
Graphic shows: Automatic transmission
Scheme 123
64 00 000 Information on using cleaning agent/paints (personal protection equipment)
| WARNING | Use of cleaning agents/paints not compliant with instructions can cause serious injuries or burns! Handling cleaning agents/paints can trigger allergic skin and respiratory reactions! |
| IMPORTANT | Observe following instructions: Store cleaning agents/paints only in a secure cabinet. Keep cleaning agents/paints away from naked flames and other sources of ignition. Protect cleaning agents/paints from high temperatures and direct sunlight. Always keep an eye bath on hand, change the water regularly (once a month). |
| IMPORTANT | Observe following instructions before use: Manufacturer's instructions (on container/packaging) Hazard warnings (on container/packaging) Manufacturer's instructions on package insert Material safety data sheet of manufacturer Product information in EPC National market regulations |
| IMPORTANT | Observe following instructions during use: Do not eat, drink or smoke while working with these products. Avoid direct contact with skin and eyes. Wear personal protective clothing/equipment. Ensure that all enclosed areas are well ventilated or extract fumes directly. Immediately change working clothes soiled with cleaning agent/paint. After finishing work, wash your hands and apply protective skin cream. |
| IMPORTANT | Follow hazard warnings and wear personal protection equipment! |
First Aid
- If product comes in contact with eyes, immediately flush with running water for about 10 - 15 minutes. Seek the advice of eye specialist.
- In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas immediately with soap and water and then apply silicone-free skin cream. Seek advice of physician.
- If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-2 glasses of water. Do not induce vomiting. Consult a doctor.
- After inhaling vapors ensure ample supply of fresh air. Keep calm, keep respiratory tracks clear and call doctor.
Recycling
Dispose of cleaning agents/paints in a professional manner!
Observe national/country-specific disposal regulations.
28 10 020 Removing and installing or replacing combination sensor (GS7D36SG)
| IMPORTANT | After completion of work, check oil level . . Use only the DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Necessary preliminary work
- Remove «twin-clutch gearbox»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
- Remove «clutch»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-40-010-removing-and-installing)
Release screw (1).
Release combination sensor (2) from housing.
Disconnect connector (3).
Installation note
Replace screw.
Scheme 124
| IMPORTANT | Do not where possible release cable (4) from bracket (5). |
Installation note
If bracket (5) does have to be released, replace aluminum screw (6).
Tightening torque, see 28 10 11AZ in 28 10 HOUSING WITH ADD-ON PARTS .
| IMPORTANT | To disconnect the combination sensor connector: Press lock together in area (1) and simultaneously detach connector. |
Scheme 125
28 10 010 Removing and installing or replacing pump unit (GS7D36SG)
| IMPORTANT | After completion of work, check oil level . . Checking/topping up oil level in twin-clutch gearbox (GS7D36SG). Use only the approved transmission oil DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Necessary preliminary work
- Remove «twin-clutch gearbox»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
- Remove «clutch»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-40-010-removing-and-installing)
Release screws (1).
Tightening torque, see 28 10 7AZ in 28 10 HOUSING WITH ADD-ON PARTS .
Remove oil separator (2).
Scheme 126
Release screw (1).
Tightening torque, see 28 10 6AZ in 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 8AZ in 28 10 HOUSING WITH ADD-ON PARTS .
Installation note
Observe installation position and screw length.
Replace sealing washer on screw (2).
Scheme 127
Release screws (1).
Tightening torque, see 28 10 9AZ in 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 128
| IMPORTANT | The pressure pipe must not be detached from the pump. |
| IMPORTANT | Before installing oil pump: Depending on version, there is a bore hole and a recess for the O-ring (1). If the bore hole is present, attention must be paid to ensuring the O-ring (1) is in the right installation position and correctly seated behind the pump. |
Scheme 129
| IMPORTANT |
Installation sequence, oil pump
- Moisten O-ring with transmission oil
- Position pump in transmission using centering sleeves.
- Gently insert screws (1) with pressure pipe
- Press in return line (2) until it audibly snaps into place
- Screw in oil pump
- The tightening sequence from 1-8 is mandatory
Scheme 130
Installation note
Centering sleeves must not be damaged or crushed.
| IMPORTANT |
Scheme 131
28 10 000 Replacing suction filter (GS7D36SG)
| IMPORTANT | After completion of the work, check the oil level . . Use only the approved DCTF-1 Pentosin (P/N 83 22 2 147 477). |
Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox.
Recycling
Catch and dispose of escaping transmission oil.
Observe country-specific waste disposal regulations.
Necessary preliminary work
- Remove «TRANSMISSION SUMP»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-02-020-removing-and-installing) .
Release screw (1).
Tightening torque, see 28 10 12AZ in 28 10 HOUSING WITH ADD-ON PARTS .
Pull suction jet pump (2) out of housing.
Installation note
Moisten seals with transmission oil before installing.
Replace suction jet pump.
Scheme 132
Release screws (1) and (2).
| IMPORTANT | Screws have different torques. |
Tightening torque, see 28 10 13AZ in 28 10 HOUSING WITH ADD-ON PARTS .
Pull suction filter out of housing.
Installation note
Moisten seal with transmission oil before installing.
Scheme 133
28 40 000 Removing and installing or replacing clutch cover (GS7D36SG)
| IMPORTANT | It is essential to adhere to conditions of absolute cleanliness. Any dirty parts must be cleaned before removing the clutch cover. After completion of work, check oil level .. Use only the approved DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Installation note
- Removal and installation of clutch cover: Replace «shaft seal for clutch cover»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-40-050-replacing-shaft-seal) , O-ring and snap ring.
- Replacement clutch cover: Replace as a single assembly only (incl. radial shaft seal, O-ring, bearing, retaining plate and snap ring).
Necessary preliminary work
- Remove «twin-clutch gearbox»(/bmw/z4/e89-2009-2013/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 transmission oil and check oil level . .
Lever snap ring (1) out of housing with a suitable tool.
Installation note
Replace snap ring.
Scheme 134
Graphic shows: Twin-clutch gearbox S65 Slip bush 23 0 390 must be used when clutch cover is removed and installed.
Pull clutch cover with special tool 13 5 250 and adapter 54 0 163 out of housing.
| IMPORTANT | Ensure uniform (non-tilting) detachment by alternately using the 3 tightening threads. |
Scheme 135
Graphic shows: Twin-clutch gearbox S65 Remove oil fouling with fluff-free cloth.
Clean snap ring groove before installing clutch cover.
Press clutch cover (1) into housing with arrow pointing up and strike evenly with a plastic hammer.
Then secure clutch cover with snap ring.
Make sure snap ring is correctly fitted.
Scheme 136
Installation note
Moisten O-ring and radial shaft seal with gearbox oil.
28 40 020 Removing and installing or replacing clutch support (GS7D36SG)
| IMPORTANT | After completion of work, check oil level . . Use only the approved DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Necessary preliminary work
- Remove «twin-clutch gearbox»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
- Remove «clutch»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-40-010-removing-and-installing)
Remove pump unit .
Unfasten screws (2).
Remove clutch support (3).
Installation note
Replace screws and seal.
Scheme 137
| IMPORTANT | Before installing clutch support: Make sure without fail that seal (1) is installed in correct position and piston rings are correctly fitted on drive shaft. Secure clutch support screw connections in diagonal sequence. |
Scheme 138
28 40 050 Replacing shaft seal for clutch cover (GS7D36SG)
| IMPORTANT | It is essential to adhere to conditions of absolute cleanliness. Any dirty parts must be cleaned before removing the clutch cover. |
Necessary preliminary work
- Remove «clutch cover»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-40-000-removing-and-installing)
To prevent the transmission oil from spilling out, tilt the gearbox back before removing the clutch cover.
Installation note
After completion of work, check oil level . .
Use only the DCTF-1 Pentosin (P/N 83 22 2 147 477) approved transmission oil.
Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox.
Use a suitable tool to take the radial shaft seal (1) off the clutch cover.
| IMPORTANT | Risk of damage: Damage to the clutch cover will result in oil leaks! If the clutch cover was damaged on removing the radial shaft seal, it is imperative that the cover be replaced. |
Scheme 139
Place the clutch cover (1) out flat on a workbench.
| IMPORTANT | Pay attention to lug (2). |
Coat sealing lips of radial shaft seal with transmission oil.
Press the radial shaft seal (3) lightly into the clutch cover.
Scheme 140
Use special tool 24 2 370 to drive the radial shaft seal into the clutch cover until the sealing ring is flush.
Scheme 141
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 142
28 40 010 Removing and installing or replacing twin clutch (GS7D36SG)
| IMPORTANT | After completing work: Check oil level .. Use only the DCTF-1 Pentosin (P/N 83 22 2 147 477) approved transmission oil. . Perform clutch adaptation (Service Functions). Teach in valve characteristics (Service Functions). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
| IMPORTANT | Twin-clutch gearbox must be on neutral (position "N") prior to removal of clutch or gear box! Gear shifts are only possible with the engine running. To prevent the transmission oil from spilling out, set the gearbox upright before removing the twin clutch. |
Necessary preliminary tasks
- Remove twin-clutch gearbox
- Remove «clutch cover»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-40-000-removing-and-installing)
Scheme 143
Push parking lock lever (1) all the way up and secure it with cable strap (2).
Scheme 144
Rotate drive shaft (1) until holes (2) are directly visible.
Check clearance with a suitable tool.
Scheme 145
Install special tool 23 0 400 and turn anticlockwise to release clutch (approx. 8 turns).
Pull clutch out of housing.
Installation note
Set gearbox upright.
The clutch is correctly installed if the oil pump gear turns.
Install the clutch with special tool 23 0 400 while constantly rotating.
Turn clockwise up to stop, then screw down to torque.
Tightening torque, see 28 40 1AZ in 28 40 DOUBLE CLUTCH GEARBOX (DKG) .
Scheme 146
| IMPORTANT | Warning: Installing the clutch may involve the danger of injury! |
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.
| IMPORTANT | When reinstalling the clutch, check that piston rings (1) and needle bearing (2) are present and correctly seated on the clutch support. Mount clutch carefully to clutch support/do not tilt, to avoid damaging the piston rings (1). |
Scheme 147
28 60... Notes on mechatronics (GS7D36SG)
| IMPORTANT | After completing work: Load specific data status with the BMW diagnosis system Check oil level . Use only gear oil for dual clutch transmission GS7D36SG DCTF-1 Pentosin (P/N 83 22 2 147 477). . Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Unscrew plug (1) and disconnect.
Scheme 148
Insert special tool 24 2 390 in sealing sleeve (1).
28 60 010 Removing and installing mechatronics (GS7D36SG)
Note. When replacing mechatronics
- Import present transmission data into new mechatronics
| IMPORTANT | It is essential to adhere to conditions of absolute cleanliness. Any dirty parts must be cleaned before the hydraulic cap is loosened. After completion of work, check oil level .. USE ONLY THE APPROVED gear oil for dual clutch transmission GS7D36SG DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Necessary preliminary tasks
- Read out transmission data of mechatronics to be replaced
- Remove «twin-clutch gearbox»(/bmw/z4/e89-2009-2013/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 points upward.
Remove hydraulic cap .
Scheme 149
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.
| IMPORTANT | Bridge (4) of connector must not break. Wiring harness must be replaced if bridge breaks. |
Scheme 150
CPA (1) in second locking position.
Installation note
Press CPA pin down until it is flush with the housing.
Scheme 151
Scheme 152
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 153
| IMPORTANT | Check the installation location of the centering pins (1). The centering pins (1) of the mechatronics remain in the housing. |
Scheme 154
Installing mechatronics
Install a new metal bead gasket.
Install mechatronics.
Fit mounting template.
Scheme 155
| IMPORTANT | Adhere without fail to the screwing sequence indicated on the template. |
The screw length can be checked by means of the insert pockets shaped in the template.
- Insert screws in sequence 1-12 and pre-tighten to 2 Nm.
- Tighten down screws 1-12 to tightening torque and angle of rotation.
- Tighten down screws in sequence 13-20 to 5 Nm.
- Remove mounting template.
28 60 030 Removing and installing/replacing the hydraulic cap (GS7D36SG)
| IMPORTANT | It is essential to adhere to conditions of absolute cleanliness. Any dirty parts must be cleaned before the hydraulic cap is loosened. After completion of work, check oil level .. Use only the DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Necessary preliminary work
- Remove «twin-clutch gearbox»(/bmw/z4/e89-2009-2013/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.
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 1AZ in 28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS .
Scheme 156
28 60 514 Replacing mechatronics (GS7D36SG)
Note. When replacing mechatronics: Import present transmission data into new mechatronics
| IMPORTANT | It is essential to adhere to conditions of absolute cleanliness. Any dirty parts must be cleaned before the hydraulic cap is loosened. After completion of work, check oil level .. Use only the approved transmission oil DCTF-1 Pentosin (P/N 83 22 2 147 477). Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Necessary preliminary tasks
- Read out transmission data of mechatronics to be replaced
- Remove «twin-clutch gearbox»(/bmw/z4/e89-2009-2013/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 .
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.
| IMPORTANT | Bridge (4) of connector must not break. Wiring harness must be replaced if bridge breaks. |
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.
| IMPORTANT | Check the installation position of the centering pins (1). The centering pins (1) of the mechatronics remain in the housing. |
The new mechatronics are supplied with the shift piston in neutral position as illustrated.
Scheme 157
In the gearbox the gearshift rods must be set to neutral position (N) as illustrated before the new mechatronics are fitted.
Scheme 158
Installing mechatronics
Install a new metal bead gasket.
Install mechatronics.
Fit mounting template.
| IMPORTANT | Adhere without fail to the screwing sequence indicated on the template. The screw length can be checked by means of the insert pockets shaped in the template. Insert screws in sequence 1-12 and pre-tighten to 2 Nm. Tighten down screws 1-12 to tightening torque and angle of rotation. See 28 60 2AZ in 28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS . Tighten down screws in sequence 13-20 to 5 Nm. Remove mounting template. |
28 60 000 Replacing pressure filter (GS7D36SG)
| IMPORTANT | It is essential to adhere to conditions of absolute cleanliness. Any dirty parts must be cleaned before the hydraulic cap is loosened. After completion of work, check oil level . . Use only the DCTF-1 Pentosin (P/N 83 22 2 147 477) approved transmission oil. Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
Recycling
Catch and dispose of escaping transmission oil.
Observe country-specific waste disposal regulations.
Necessary preliminary work
- Remove underbody protection at front and rear. See «51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION»(ref-381258-S36346312162010122800000)
- Remove «EXHAUST SYSTEM»(/bmw/z4/e89-2009-2013/remont/exhaust/#exhaust-system-repair-n54__18-00-020-removing-and-installing)
- Remove «PROPELLER SHAFT»(/bmw/z4/e89-2009-2013/remont/driveshaft-universal-joints/#propeller-shaft-repair-n54__26-11-000-removing-and-installing)
Supporting transmission
Support transmission with special tools 23 4 050 , 00-2030 DEVICE .
Secure transmission with tensioning strap (1).
Tasks are described in Gearbox holder .
After completion of work, check oil level .
Lower engine with transmission until pressure filter lid (1) is accessible.
Remove retainer (2).
Installation note
Replace retainer.
Scheme 159
Lever out lid (1) with sealing ring.
Installation note
Replace lid with sealing ring.
Lubricate sealing ring with transmission oil before installing.
| IMPORTANT | Catch and dispose of escaping transmission oil. |
Scheme 160
Remove pressure filter (1).
Scheme 161
28 60 020 Replacing wiring harness (GS7D36SG)
| IMPORTANT | After completion of work, check oil level . . Use only the approved DCTF-1 Pentosin (P/N 83 22 2 147 477) transmission oil. Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox. |
| IMPORTANT | Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) . |
Necessary preliminary work
- Remove «twin-clutch gearbox»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
- Remove «mechatronics»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-60-010-removing-and-installing)
- Remove «clutch»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-40-010-removing-and-installing)
Release screw (1).
Scheme 162
Release screw (1).
Tightening torque, see 28 10 6AZ in 28 10 HOUSING WITH ADD-ON PARTS .
Release aluminum screw (6).
Tightening torque, see 28 10 11AZ in 28 10 HOUSING WITH ADD-ON PARTS .
Installation note
Replace aluminum screw.
Release combination sensor (2) from housing.
Disconnect connector (3).
Removing wiring harness (4) with earth terminal (5) from housing.
| IMPORTANT | Guide earth terminal (5) carefully through transmission connector bore. |
Risk of damage to sealing surface.
| IMPORTANT | To disconnect the combination sensor connector: Press lock together in area (1) and simultaneously detach connector. |
See also:
• TRANSMISSION OIL COOLER TOGETHER WITH LINES
• 28 00 DOUBLE CLUTCH GEARBOX
• BATTERY NEGATIVE LEAD
• EXHAUST SYSTEM
• 23 4 050
• TRANSMISSION HOLDER
• 22 32 3AZ/4AZ
• 24 2 390
• 00 9 130 MAGNET
• EXHAUST SYSTEM
• 23... UNIVERSAL BMW TRANSMISSION TAKE-UP
• 23 0 020
• 28 10 HOUSING WITH ADD-ON PARTS
• 331 150 DEVICE
• ESD PROTECTION (ELECTRO STATIC DISCHARGE)
• 13 5 250
• 28 40 DOUBLE CLUTCH GEARBOX (DKG)
• 28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS
• oil level
• PROPELLER SHAFT
• twin-clutch gearbox
• clutch
• TRANSMISSION SUMP
• shaft seal for clutch cover
• pump unit
• clutch cover
• hydraulic cap
• mechatronics