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Remove retainer (1).

Withdraw selector rod (3) from selector linkage jointand remove washers (2).

Installation:Apply thin coat of grease to selector rod.

Grease, refer to BMW Service Operating Fluids.

13

2

36 25 018 E

23 00 022 Removing and installingtransmission (S5D 200G,S5D 250G)

Note:After completion of the work, check transmission oil

level,refer to 00 11 229.

On vehicles with ASC+T, the throttle body and/or theexpansion tank on the master brake cylinder canbecome damaged when the transmission is lowered.

Remove throttle body (ASC+T),refer to 13 54 060.

Disconnect battery,

refer to instructions on disconnecting and connectingbattery in MG 12.

Disconnect propeller shaft from transmission flangeand tie up to one side,

refer to 26 11 000.

Unfasten nuts and remove clutch slave cylinder(pressure line remains connected).

Caution!Relieve clutch slave cylinder slowly, as otherwise air

will be sucked in via the sealing sleeve.

Installation:

Tightening torque,refer to Technical Data 21 52 5AZ.

36 21 007 U

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Pull wires off reverse-gear switch.

Loosen oxygen-sensor connector in holder.

36 23 010 U

Remove cross tube.

roadster:

Remove reinforcement bracket.

R 24 0046

Engine M40:

Remove end fire wall,refer to 61 61 270.

Unscrew cable duct from rear end of engine.

Mount special tool 00 0 200 and hook it into the eye on

the crankcase.

Tighten spindle (1).

1

00 0 200

36 23 025 U

M50/M52 engine:

Remove end fire wall,refer to 61 61 270.

Unscrew injection pipe cover (1). Screw special tool

11 0 030 down through intake manifold and into bracketof crankcase.

Fit special tool 00 0 200 and attach to special tool11 0 030.


36 23 024 U

2

1

11 0 030

00 0 200

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M41/M43 engine:

Attach special tool 11 8 022 to left and right controlarms.

Caution!Locate special tool in such a position that engine oil

pan rests securely on special tool.

Tighten down knurled screws until special tool makes

contact with engine oil pan.

11 8 022

36 23 028 E

Support transmission with a workshop hoist.

Unfasten screws and remove cross member withrubber mount.

Lower workshop hoist.

Installation:Tightening torque,refer to Technical Data 23 71 1AZ/2AZ.

36 23 011 U

M40/ M42/ M50/ M52 engine:

Lower engine and transmission with spindle (2) untilcylinder head and manifold are just above, but not in

contact with, engine fire wall or heating connections(visual check).

36 23 024 U

2

1

11 0 030

00 0 200

M41/M43 engine:

Lower engine and transmission by unfastening knurledscrews until cylinder head and manifold are just above,but not in contact with, engine fire wall or heating

connections (visual check).

36 23 029 E

11 8 022

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Use a screwdriver to lift out spring (1) from the lug (2)on the housing and swivel upwards.

Pull out shaft.

Installation:Apply thin coat of grease to bearing pin.


36 25 024 U

1

2

Support transmission with workshop hoist.

Unfasten screws.

Caution!Do not allow transmission to hang on transmissioninput shaft when removing and installing, as the clutch

disc will be deformed.

Pull transmission downwards and remove.

Installation:Always fit screws with washers.


BWM

32 23 010 E

Installation:

Note dowel sleeves (1 ... 2) and replace if necessary.

Ensure correct position of cover plate.

34 23 011 E

1

2

Installation:Remove release unit and release lever and apply grease

to appropriate points,refer to 21 51 500.

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Installation:Check lubrication of transmission input shaft for sticky

consistency. If the grease is sticky, the clutch disc mustbe replaced,

refer to 21 21 500.

Check clutch disc for friction rust in taper splines and

replace if necessary,refer to 21 21 500.

Mechanically remove old grease and lining abrasionfrom the taper splines of the clutch disc (with a cloth).

Clean spline grooves and guide spigots ontransmission input shaft and apply a thin coat of

grease.32 23 043 E

The volume of grease required for this correspondsroughly to the size of a corn on the cob.


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Remove retainer (1).

Withdraw selector rod (3) from selector linkage jointand remove washers (2).

Installation:Apply thin coat of grease to selector rod.


13

2

36 25 018 E

23 00 023 Removing and installingtransmission (S5D 260Z, S5D 310Z)

Note:After completion of the work, check transmission oillevel,

refer to 00 11 229.

On vehicles with ASC+T, the throttle body and/or the

expansion tank on the master brake cylinder canbecome damaged when the transmission is lowered.

Remove throttle body (ASC+T),refer to 13 54 060.

Disconnect battery,refer to instructions on disconnecting and connecting

battery in MG 12.

Disconnect propeller shaft from transmission flangeand tie up to one side,refer to 26 11 000.

Unfasten nuts and remove clutch slave cylinder(pressure line remains connected).

Caution!Relieve clutch slave cylinder slowly, as otherwise air

will be sucked in via the sealing sleeve.

Installation:


36 21 007 U

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Pull wires off reverse-gear switch.

Loosen oxygen-sensor connector in holder.

36 23 010 U

Remove cross tube.

R 24 0046

M50/M52 engine:

Remove end fire wall,refer to 61 61 270

Unscrew injection pipe cover (1). Screw special tool11 0 030 down through intake manifold and into bracket

of crankcase.

Fit special tool 00 0 200 and attach to special tool

11 0 030.


36 23 024 U

2

1

11 0 030

00 0 200

Engine M51:

Remove cover from manifold.Secure special tool 11 2 370 on intake pipe, rear.

Assemble special tool 00 0 200 and attach to specialtool 11 2 370.

Tighten spindle.

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S50 engine:






11 8 022

36 23 028 E


Unfasten screws and remove cross member withrubber mount.

Lower workshop hoist.

Installation:Tightening torque,refer to Technical Data 23 71 1AZ/2AZ.

36 23 011 U

M50/M52 engine:

Lower engine and transmission with spindle (2) untilcylinder head and manifold are just above, but not in

contact with, engine fire wall or heating connections(visual check).

36 23 024 U

2

1

11 0 030

00 0 200

S50 engine:

Lower engine and transmission by unfastening knurledscrews until cylinder head and manifold are just above,but not in contact with, engine fire wall or heating

connections (visual check).

36 23 029 E

11 8 022

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S50 engine:

Secure special tool 11 8 021 to front axle support.

Screw up stud (1) enough for it to bear on oil sump.

(Support prevents engine from tilting forward afterremoving transmission.)

36 23 030 E

1 11 8 021

Use a screwdriver to lift out spring (1) from the lug (2)on the housing and swivel upwards.

Pull out shaft.

Installation:Apply thin coat of grease to bearing pin.


36 25 024 U

1

2


Unfasten screws.

Caution!

Do not allow transmission to hang on transmissioninput shaft when removing and installing, as the clutch

disc will be deformed.


Installation:Always fit screws with washers.


BWM

32 23 010 E

Installation:Note dowel sleeves (1 ... 2) and replace if necessary.


34 23 011 E

1

2

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Installation:Remove and clean release unit and release lever and

grease appropriate points,refer to 21 51 500.



refer to 21 21 500.



Mechanically remove old grease and lining abrasionfrom taper splines of clutch disc (with a cloth).


grease.32 23 043 E

The volume of grease required for this corresponds

roughly to the size of a corn on the cob.


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displayed. Also, no further gear change noises can be

heard from the transmission.

Switch off ignition.

Disconnect battery,refer to Instructions on disconnecting and connecting

battery in MG 12.

23 00 025 Removing and installingtransmission (S6S 420G SMG)

After finishing work:

Checking transmission oil level,refer to 00 11 229.

Bleed hydraulic system. To do this, perform bleed

routine with BMW Diagnosis System.

Perform transmission adaption with BMW DiagnosisSystem.

Check oil level in hydraulic system (SMG),

refer to 21 53 501.

Caution!Depressurize hydraulic system. This involves:

Opening cover on E-box on right spring strut shock

absorber and pulling off relay (1).

Switch on ignition.

Actuate brake.

Shift selector lever from position 0 toR and/or0 to E until the transmission stops performing gearchanges.

Note:The gear display on the instrument cluster starts to

flash and/or the engaged driving range ceases to be

1

R23 0092

Open expansion tank (1) and reservoir (2) and drawhydraulic fluid out of both containers.

2

1

R21 0043

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Installation:Fill expansion tank (1) with hydraulic fluid

(Pentosin CHF 11S).

Release bleed screw (3) on supply tank (2) and wait

until hydraulic fluid emerges from bleed screw (3).

The filling procedure can be sped up if the expansion

tank (1) is pumped up a little with special tools 21 5 010and 17 0 002.

Close bleed screw (3).

Fill expansion tank (1) up to MAX mark (dipstick (4) on

cover).

2

3

4

1

R21 0051

Remove end panel on heating,refer to 61 61 270.

Remove splash guard.

Remove complete exhaust system,refer to 18 00 020.

Remove bracket (1) for underbody protection.

R23 0096

1

Remove heat shield (1).

Remove heat shield from right transmission cross-member.

36 26 010 U

1

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Remove brackets (1... 2) for exhaust suspension (only iffitted).

Remove reinforcement (3).

Installation:Remove reinforcement (3) with long collar (4) facing

forwards.

1

3

4

2

36 26 011 U

Release screws

Installation:Replace self-locking nuts.

Fit screws with shim.

When tightening down, brace screw and turn nut. This

prevents the flexible coupling from being subjected totorsion stress.

Tightening Torque,refer to Technical Data 26 11 1AZ.

R23 0094

Brace propeller shaft on center mount and loosen nuts.

R26 0014

Installation:Center bearing must be aligned at right angles to

propeller shaft.

Tighten centre bearing in direction of travel (A = 2 ... 4

mm)


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Caution!Do not let propeller shaft fall into joints. In particular, on

the constant velocity joint, the rubber sleeve getssquashed or the joint is damaged.

Bend the propeller shaft downwards from the centrebearing, remove from the transmission output flange

and secure to the side of the underbody with a piece ofstring or wire.

31 26 014 E

Unfasten nuts and remove clutch slave cylinder

(pressure line remains connected).

Caution!

Relieve clutch slave cylinder slowly, as otherwise airwill be sucked in via the sealing sleeve.

Installation:Tightening Torque,

refer to Technical Data 21 52 5AZ

36 21 007 U

Pull cable connector (1) off reverse gear switch.

1

R23 0093

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Pull cable connector (1) off cable on speed sensor.

R23 0095

1

Pull cable connector (1) off transmission oiltemperature sensor.

R23 0098

1

Unfasten cable connector (1) (switch for gear

recognition) from the bracket and disconnect.

R23 0099

1

Unfasten and disconnect cable connector (1) onLambda oxygen sensor bracket. Unfasten cable from

bracket on transmission cross member.

R23 0097

1

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Loosen nut (1).

Pull retaining clip (2) off and remove cable (3) frombracket (4).

Installation:Adjust cable,

refer to 25 16 ... .

R23 0100

2

1

3

4

Pull off retaining clip (1) and cable (2) from bracket (3).

R23 0101

2

13

Unfasten screws and remove transverse tube (1).

Installation:Tightening Torque,

refer to Technical Data 41 11 1AZ.

R23 0102

1

Disconnect hydraulic lines (1... 3) and seal with suitableplastic plugs.

Unscrew holder (4).

Installation:Tightening Torque,refer to Technical Data 21 52 1AZ.

R23 0103

41

2

3

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Support transmission with special tool 00 2 030 /23 0 040 / 23 0 042.

23 0 042

00 2 030

23 0 040

R23 0104

Caution!Do not support or lift transmission from switch for gear

recognition (1).

R23 0118

1

Release screws

Only lower transmission until cylinder head andmanifold almost make contact with engine fire wall and/

or heating connections (visual inspection).Installation:

Tightening Torque,refer to Technical Data 23 71 2AZ

R23 0105






11 8 022

36 23 028 E

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Secure special tool 11 8 021 to front axle support.

Turn screw (1) upwards until it is flush with the oil pan.

Note:This support prevents the engine from tilting forwardswhile the transmission is being removed.

36 23 030 E

1 11 8 021

Release screws

Caution!Do not allow transmission to hang on transmission

input shaft when removing and installing, as the clutchdisc will be deformed.


BWM

32 23 010 E

Installation:

Always fit screws (1) with narrow collar using shims.

Fit screws (2) with wide collar without any shims.


1 2

R23 0117

Installation:Note dowel sleeves (1 ... 2) and replace if necessary.


34 23 011 E

1

2

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Installation:Remove and clean release unit and release lever and

grease appropriate points,refer to 21 51 500.



refer to 21 21 500.



Mechanically remove old grease and lining abrasionfrom taper splines of clutch disc (with a cloth).


grease.32 23 043 E

The volume of grease required for this corresponds

roughly to the size of a grain of maize.


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Transfer shift-rod joint.

Slide back retaining sleeve or retaining ring (1).

Drive out cylindrical pin (2).

31 23 030 U

12

23 00 032 Installing exchange transmission(S5D 200G/250G)

Note:Removing and installing transmission (S5D 200G/250G),

refer to 23 00 022.

Installing release unit and release lever in the newtransmission,

refer to 21 51 500.

Transfer exhaust carrier and backup light switch.

Note:Transmissions are supplied filled with oil.

For this reason it is only necessary to check oil level

after installation of transmission.

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Installing release unit and release lever in the new

transmission,refer to 21 51 500.

23 00 033 Installing replacementtransmission (S5D 260Z/310Z)

Note:Removing and installing transmission (S5D 260Z/310Z),refer to 23 00 023.

Note:Before installing the transmission, fit breather (1) (refer

to sticker).

Remove breather (1) and protective sleeve (2) fromselector shaft.

Lift off sealing cap (3) and install breather (1).

36 23 013 U

3

2

1

Transfer shift-rod joint.

Slide back retaining sleeve or retaining ring (1).Drive out cylindrical pin (2).

31 23 030 U

1

2

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Transfer exhaust carrier and backup light switch.

Note:Transmissions are supplied filled with oil.

For this reason it is only necessary to check oil levelafter installation of transmission.

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Brace output flange with special tool 23 0 020.

Unfasten collar nut (1) with special tool 23 2 320.

Installation:

Install collar nut (1) with screw retainer: for screwretaining compound, refer to BMW Parts Service.


23 0 02034 23 124 U

23 2 320

1

23 12 055 Replacing radial seal for outputflange (S5D 260Z/ 310Z)

After completion of work, check transmission oil level,refer to 00 11 229.


refer to 26 11 000.


Unfasten screws and remove cross-member.

Installation:Tightening torque,refer to Technical Data 23 71 1AZ/ 2AZ.

36 23 011 U

Remove output flange from transmission output shaftwith special tool 33 1 150.

Installation:Heat output flange to approx. 80 C and slide onto

transmission output shaft.

36 23 103

33 1 150

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Remove radial seal with special tool 00 5 010.

36 23 022 U

00 5 010

Coat sealing lips of new radial seal (3) withtransmission oil.

Drive radial seal (3) home flush with special tool

23 2 300.

Note:

Use plastic hammer to drive in.

23 2 300

34 23 135 U

3

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Unfasten collar nut with special tool 23 1 210.

Installation note:

Install collar nut with screw retaining compound: forscrew retainer refer to BMW Parts Service.


23 1 210

23 0 020

36 23 102

23 12 056 Replacing radial seal for outputflange (S5D 200G/ 250G)

After completion of work, check transmission oil level,refer to 00 11 229.


refer to 26 11 000.

If necessary, lift out retaining plate (1).

Installation note:Do not fit retaining plate.

36 23 101

1

Remove output flange from transmission output shaftwith special tool 33 1 150.

36 23 103

33 1 150

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36 23 022 U

00 5 010

Coat sealing lips of new radial seal with transmissionoil.

Drive in radial seal flush with special tool 24 0 110.

36 23 023 U

24 0 110

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Pry out radial sealing ring (3) with a narrow screwdriver.

36 23 019 U

3

23 12 085 Replacing radial seal on selectorshaft (S5D 260Z/310Z)

Unflange propeller shaft from transmission and tie upto one side,

refer to 26 11 000

Push back locking sleeve (1) and drive out cylindricalpin (2).

1

36 23 018 U

2

Drive in radial seal (1) with special tool 23 2 260.

23 2 260

34 23 147 U

1

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Pry out radial sealing ring (3) with a narrow screwdriver.

36 23 019 U

3

23 12 086 Replacing radial seal on selectorshaft (S5D 200G/250G)

Unflange propeller shaft from transmission and tie upto one side,

refer to 26 11 000

Push back locking sleeve (1) and drive out cylindricalpin (2).

1

36 23 018 U

2

Lubricate sealing lip of radial seal ring with oil.

Drive in radial seal flush with special tool 23 1 240.Check oil level, correcting if necessary.

23 1 240

36 23 020 U

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Probe bores (1 and 2) with a scribing tool and push right

through.

Drive in radial sealing ring at one end as far as stop.

Screw a suitable self-tapping screw into opposite bore.

Use pliers to pull out radial sealing ring on self-tapping

screw.

34 23 108 U

1

2

23 12 505 Replacing radial seal on input shaft(S5D 260Z/ 310Z)

Note:Transmission removed.

Removing release unit and release lever,refer to 21 51 500.

Unfasten screws and remove guide tube.

Installation note:Tightening torque,


34 23 104 U

Coat sealing lips of new radial seal with transmissionoil.

Drive in radial seal (1) flush using special tool 23 2 340.

Caution!Use a plastic hammer for driving in seal.

34 23 221 U

23 2 340

1

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Probe bores (1 and 2) with a scribing tool and push right

through.

Drive in radial sealing ring at one end as far as stop.

Screw a suitable self-tapping screw into opposite bore.

Use pliers to pull out radial sealing ring on self-tapping

screw.

34 23 108 U

1

2

23 12 506 Replacing radial seal on input shaft(S5D 200G/ 250G)

Note:Transmission removed.

Removing release unit and release lever,refer to 21 51 500.


Installation note:Install screws with screw retaining compound

Loctite 242.

Screw retaining compound, refer to BMW Parts Service.


36 23 242

Fit special tool 23 2 460 to the transmission input shaft.

Coat sealing lips of new radial seal (1) withtransmission oil and slide firmly home on transmissioncase.

Remove special tool 23 2 460 from the transmissioninput shaft.

36 23 220

1

23 2 460

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Drive radial seal (1) firmly home with special tool23 2 430.

23 2 430

1

36 23 221

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23 .. ... For other operations on transmission, refer to microfiche of ConstructionGroup Repair Manual

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Remove clutch release unit and release lever,

refer to 21 51 500

23 21 505 Complete removal and installationof input and output shafts(S5D 200G/ 250G)

Transmission removed.

Unscrew drain plug.

Drain off fluid.

Secure special tool 23 0 100 on the bore of the drain

plug.

Locate transmission on assembly frame 00 1 490 with

special tool 23 0 100.

36 23 100

23 0 100

00 1 490

When fitted:

Lift out lockplate (1).

36 23 101

1

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Unfasten collar nut with special tool 23 1 210.23 1 210

23 0 020

36 23 102

Pull off output flange.

Note:If output flange has ease-of-movement with special tool

33 1 150.

36 23 103

33 1 150


36 23 218

00 5 010

Remove cap (1).

36 23 104

1

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Remove compression springs (1) and cylinder pins (2).

36 23 105

1

2

Remove locking and ball stops (3) (5 off) with the helpof a magnet (4).

36 23 106

3

4

Note:

Note locking pin (1) in the centre selector rod!

36 23 107

1

Locking pin (1) on centre selector rod (2) must belocated in centre of selector rod.

Note:To secure position of locking pin (1), transmission must

be shifted into 2nd gear.

R23 0088

2

1

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Shift into 2nd gear:

Insert cotter pin extractor or screwdriver (1) in the boreof the selector shaft (2).

Turn selector shaft (2) to 1st detent anticlockwise andpress into the transmission.

R23 0061

2

1

Unfasten screws.

R23 0062

Remove sealing ring.

R23 0063

Unfasten screw (1) and reverse gear switch (2).

Lever out cap (3).

36 23 109

1

2

3

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Remove spring (4) and arrester bolt (5).

36 23 110

5

4

Unscrew screws (1 and 2).

36 23 219

1 2

Drive cotter pin (1) towards clutch housing with a cotter

pin extractor.

R23 0064

1

Drive out cotter pin (2) with a cotter pin extractor.

R23 0065

2

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Unfasten screws on transmission case (9 off).

R23 0066

Remove transmission from assembly frame 00 1 490and place to one side with output end uppermost.

Fit special tool 23 1 141 together with 23 1 142 and

23 1 143 and install on rear case section.

Pull off rear case section.

36 23 114

23 1 141

23 1 142

23 1 143

Remove centre selector rod until all 3 selector rods are

at the same height.

36 23 196

Remove retaining plate (1) and magnetic disc (2).

36 23 117

1

2

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Withdraw pin (3).

Remove pivot lever (4).

Remove gearshift rail (6).

Note:At lower end of selector shaft (5) there are 4 rollers:

these can fall out when the selector shaft is removed.

Pull out shift shaft (5).

4

5

6

336 23 118

Position gears and shafts with front case section onspecial tool 23 2 400.

36 23 119

23 2 400


36 23 120

Probe assembly apertures (1 and 2) with a scribing tooland pierce through.

Drive one side of radial seal (on an assembly aperture)to limit position in the transmission case.

Screw a self-tapping screw into the side opposite theassembly aperture and remove the radial seal on the

self-tapping screw.

36 23 121

1

2

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23/40

Caution!To avoid damaging input shaft, special tool 23 2 460

must be inserted on the input shaft during removal ofthe circlip (3).

Lift out circlip (3) and pull off over special tool 23 2 460.

36 23 197

3

23 2 460

Remove closing ring (4).

36 23 198

4

Caution!

To avoid damaging input shaft, special tool 23 2 460must be inserted on the input shaft during removal ofthe circlip (6).

Lift off circlip (6) and secure to special tool 23 2 460.

Pull special tool 23 2 460 with circlip (6) from the inputshaft.

Lift out spacer disc (5).

36 23 199

6

23 2 460

5

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23/41

Secure special tool 23 1 141 to front case section with 2screws.

Pull front case section from gears and shafts.

36 23 123

23 1 141

Take off needle bearing (1).

Remove reverse gear (3) with reverse gear shaft (2).1

2

3

36 23 128

Remove complete gear train with selector rods (1) from


36 23 130

1

Reassemble transmission:

Install complete gear train with selector rods in thespecial tool 23 2 400.

36 23 177

23 2 400

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Install reverse gear with collar (2) facing upwards andreverse gear shaft with long extension (1) in special tool

23 2 400.

Coat short extension (3) of reverse gear shaft and coatlocating face with Loctite 574 liquid gasket.

Liquid gasket,

see BMW Parts Service.

36 23 222

1

3

2

Check end float of the input shaft.

Apply special tool 23 2 420 on the input shaft.

Insert spacer disc (2) and new circlip (1) in the groove.

Check end float with a feeler gauge.

End float 0.04 mm.

Note:Spacer disc (2) is available in thicknesses (X) of2.3 ... 2.65 mm in Parts Service.

36 23 173

1

23 2 420

X

2

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Heat input shaft inner bearing race (1) in the front casesection to approx. 110 ... 120 C (hot air blower).

The heating temperature must be precisely maintained.

Check with a thermometer.

Thermometer, refer to BMW Service Workshop

Equipment Planning Documentation.

Align selector rods with one another.

After heating, insert the roller bearing (2) with thickgrease into the bearing sleeve with large diameter

facing upwards.

1

2

36 23 223

Carefully attach the front case section.

Note:The 5th gear synchronizer ring can jam.

After completely assembling the transmission, the 5thgear synchronizer ring can be loosened again by

twisting the output/input shafts against each other.

36 23 224

Install spacer (5).

Caution!To avoid damaging input shaft, special tool 23 2 460must be inserted on the input shaft while installing the

circlip (6).

Slide new circlip (6) over the special tool 23 2 460 and

install in the lower groove.

36 23 199

6

23 2 460

5

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23/44

Install closing ring (4).


must be inserted on the input shaft while installing thecirclip (3).

Slide new circlip (3) over the special tool 23 2 460 andinstall in the upper groove.

36 23 243

3

23 2 460

4

Coat the radial seal sealing lip with ATF-oil. Push radialseal (1) over special tool 23 2 460 up to case.

Remove special tool 23 2 460.

36 23 225

1

23 2 460


Use plastic hammer to drive in.

36 23 226

1

23 2 430

Install guide tube.

Install screws with Loctite 243 screw locking varnish.Screw retaining compound, refer to BMW Parts Service.


36 23 120

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Secure reverse gear shaft on front case section.

Install screw (1) with Loctite 243 screw locking varnishand tighten.

Screw retaining compound, refer to BMW Parts Service.

Tightening torque,


Loosen screw (2) from special tool 23 2 400.

1

36 23 182

2

Remove front case section and gear train from specialtool 23 2 400 and place to one side with output end

uppermost.

36 23 201

23 2 400

Attach 4 rollers to the selector shaft with Vaseline.

36 23 183

Insert selector shaft (1) into front case section.

Insert gearshift rail (2) with the opening upward into thecase.

1

2

36 23 184

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23/46

Install pivot lever with the broader head (1) facing theselector rod (2).

Polished side must face towards case.

Attach pivot lever with the pin (3).

1

2

336 23 227

Install locking pin (1) in the selector rod (2) withVaseline and secure in centre.

36 23 228

21

Clean case sealing surfaces and coat with Loctite 547

gasket compound.

Place retaining plate (1) on 2nd gear of countershaft

with flat side facing upwards. Screw special tool23 2 440 into the retaining plate (1)

Place magnetic disc (2) in the case. Align selector rodswith one another. Coat reverse gear shaft (3) on the

locating face with Loctite 574 liquid gasket compound.

Gasket compound, refer to BMW Parts Service.

23 2 440

1

2

3

36 23 229

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23/47

Lift out radial seal of selector shaft from the rear case.

Heat inner bearing race (1) and rear case section in areaaround bearing to 110 ... 120 C (hot air blower).



36 23 230

1

Insert rear case section up to limit stop. Install 3 screwswith new sealing rings. Remove special tool 23 2 440.

Screw in fourth screw with new sealing ring.

Tighten down all screws.

Tightening torque,


36 23 187

23 2 440

Lightly secure front and rear case sections with

opposite two screws.

Place rear case section on support 23 0 100 and again

lift with the assembly hoist 00 1 490.

36 23 100

23 0 100

00 1 490

Drive in cotter pin (1).

R23 0064

1

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R23 0065

2

Screw in all case screws and tighten down.


36 23 111

1

Loosen bolt (1).

Install screw (2) with Loctite 243 locking varnish.

Tighten the screws (1 and 2).


36 23 219

1 2

Install radial seal for selector shaft and output shaft.

Coat sealing lip with ATF-oil.Push in output shaft radial seal with special tool24 0 110 and selector shaft radial seal with special tool

23 1 240.

Note:Use a plastic hammer for driving in seal.

36 23 188

24 0 110

23 1 240

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23/49

Heat output flange to approx. 80 C (hot air blower) andfit on output shaft.

Coat thread and locating face of collar nut (1) with

Loctite 243 locking varnish.


Tighten collar nut (1) with special tool 23 1 210.


36 23 189

23 1 210

23 0 020

1

Install arrester and locking balls.

Order:

Locking ball (1), arrester ball (2) and locking pin (3).

36 23 202

2

1

3

Install springs (1) and cylinder pins (2).

36 23 105

1

2

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Attach cap (1).

Install screws with Loctite 243 screw locking varnishand secure.

36 23 231

1

Install arrester bolt (1) and spring (2).

Note:Roller (3) must be positioned horizontally.

36 23 203

3

1

2

Install shear-off screw (1) with Loctite 243 locking

varnish and tighten down.

Install the reverse gear switch.


Knock in plug (3).

36 23 204

1

2

3

Install clutch release mechanism and release lever,refer to 21 51 500

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Unfasten screws.

If installed, remove oil deflector plate (1).

Remove retaining plate (2).

1

36 23 146

2

23 21 706 Replacing bearings on allgearshafts (S5D 200G/ 250G)


Removing input and output shafts,refer to 23 21 505

Output shaft bearings in rear case:

Place rear case section on support 23 0 100 and lift withassembly hoist 00 1 490.

36 23 232

23 0 100

00 1 490

Remove output shaft bearing with special tool 23 1 340and handle 00 5 500 from the outside to the inside.

36 23 116

00 5 500

23 1 340

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Heat the rear case section in the area near the outputshaft bearing to approx. 80 C (hot air blower). Install

bearing, using, if necessary, special tool 23 2 450 andhandle 00 5 500 until securely driven into place.

36 23 145

00 5 500

23 2 450

Clean screws and threaded bores.

Install retaining plate (2) and oil scraper plate (1).

Coat screws with Loctite 243 locking varnish and screw

into place.

Tightening torque,


1

36 23 146

2

Bearing on the countershaft:

- Hex screw with washer -

Clamp the layshaft bearing in a vise with two protective

pads (3).

Note:Screw (1) has a left-hand thread.

Unscrew bolt (1).

Take off washer (2).

Note:Instead of the hex screw (1) and the washer (2), a Torx

screw is fitted!36 23 142

2

1

3

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- Torx screw -

Clamp countershaft in a vise with protective jaws.

Note:Screw (1) has a left-hand thread.

Unscrew bolt (1).

R23 0069

1

Press bearing (2) off countershaft with a special tool23 1 250 on a hydraulic press.

R23 0070

2

23 1 250

Press inner bearing race (3) off countershaft with

special tool 00 7 500 / 23 1 250 on a hydraulic press.

R23 0071

23 1 25000 7 500

3

Note:The taper (2) on the outer bearing race must point

upwards.

Press new bearing (1) off countershaft with special tool

23 1 040 on a hydraulic press.

R23 0072

1

2

23 1 040

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Screw in new Torx screw (1) and tighten down.

Tightening torque,


R23 0069

1

Output shaft bearings in front case section:

Remove selector arm (1). For this purpose, unscrewscrews (4 and 5). Remove bracket (3), spring (2) and

selector arm (1).

Remove retaining plate (6).

36 23 124

2

1

3

5

4

6

Remove output shaft bearing with special tool 23 1 340

and handle 00 5 500 from the outside to the inside.

36 23 125

00 5 50023 1 340

Heat the front case section in the area near the bearingto approximately 80 C (hot air blower).

Install bearing, using, if necessary, special tool23 1 470 and handle 00 5 500 until securely driven into

place.

36 23 148

00 5 500

23 1 470

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Outer bearing race of countershaft in frontcase section:

Insert special tool 23 1 280 into the bearing shell (1).

36 23 126

1

23 1 280

Apply special tool 33 4 020.

Screw on special tool 23 1 300.

Pull out bearing shell.

36 23 127

23 1 30033 4 020

Installation:

Insert bearing shell (1) so that the slot in the bearingshell is aligned with beads (2) (turning lock) in the case.

34 23 213 U

12

Push in bearing shell (1) insert with special tool23 1 260 and handle 00 5 500.

Locking device (2).

36 23 147

12

23 1 260

00 5 500

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Install retaining plate.

For this purpose, push locking bolt (2) outward with ascrew (1).

Push the locking bolt (3) outward with a screwdriver (4).

Install retaining plate and secure with screws.

Install screws with Loctite 243 screw locking varnish.


Remove screw (1).

36 23 149

1

24

3

Note installation position of the pressure pin. Beveledsides must face each other inwards.

36 23 233

Install roller (1) with selector arm (2).

36 23 150

2

1

Install spring (4) and sleeve (1). Position shorter leg (K)on case and longer leg (L) in the slot on selector arm.

Coat screw-head (2) contact surface with Loctite 547gasket compound.

gasket compound, refer to BMW Parts Service.

36 23 151

1 2

3

K4

L

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To ease assembly (strong spring force), insert specialtool 23 1 250 in the selector arm and push sleeve (1) up

to the case. While in this position, install screw (2) withLoctite 243 screw locking varnish and attach loosely.

Then install screw (3) with Loctite 243 screw lockingvarnish and secure.

Tighten screw (2) last.

36 23 234

1

223 1 250

3

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Remove selector rods (1).

Separate layshaft from gears and shafts.

36 23 130

1

23 23 508 Detaching and mounting allsynchronizing devices S5D 200G/250G


Completely remove and install input and output shafts,refer to 23 21 505.

Remove gears and shafts with selector rods fromspecial tool 23 2 400.

36 23 177

23 2 400

Remove input shaft, needle bearing (1) and 5th gearsynchronizer ring.

1

36 23 174

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To ease assembly, insert the output shaft in special tool23 2 400. Pull 5th/reverse gear sliding sleeve (2) off the

guide sleeve.

Caution!Loose thrust pieces, balls and springs.

Lift out circlip (1).

Installation:

Replace circlip.

36 23 205

2

1

Rotate the output shaft so that the drive end faces up.

Double taper synchronization:Remove 1st gear wheel (1), needle bearing (2),

synchronizer ring (3), taper ring (4) and friction ring (5)from the output shaft.

36 23 132

1

2

35

4

Single taper synchronization:

Remove 1st gear wheel (1), needle bearing (2) andsynchronizer ring (3) from the output shaft.

3

1

2

36 23 206


Pull off 1st/2nd gear sliding sleeve (2).Caution!Loose thrust pieces, balls and springs.

Installation:Replace circlip (1).

36 23 133

1

2

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Separate 2nd gear wheel (2) and guide sleeve (1) fromthe output shaft by pressing.

36 23 134

1

2

Remove reverse gear wheel, synchronizer ring andguide sleeve (1) from the output shaft with special tool

23 1 490 by pressing.

36 23 136

23 1 490

1

R

Prior to assembling gears and shafts, check all

synchronizing devices for wear. For this purpose,determine gap measurement X between synchronizerring and the corresponding gears.

Measure near the detent lugs. Uniformly presssynchronizer ring in direction of taper.

Gap measurements of the individual gear wheels,

refer to Technical Data.

36 23 154

X

Assembly of gears and shafts:Connect needle bearing (1), reverse gear wheel (3) and

synchronizer ring (2).

Note:

Lightly oil needle bearing (1) and synchronizer ring (2)on bearing surfaces with ATF-oil.

36 23 164

1

3

2

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Heat guide sleeve (1), 5th/reverse gear, to approx. 120

C (hot air blower) and connect to the output shaft. If

necessary, press on with special tool 23 1 290 untiltight.

Caution!While pressing on, ensure that the detent lugs (2) catch

in the openings in the guide sleeve.

36 23 165

23 1 290

2

1

Install appropriate circlip (1). Circlips are available inParts Service from 2.0 ... 2.3 mm in increments of 0.05

mm.

Max. permissible end float X: 0.04 mm.

36 23 166

1

X

Insert 3 thrust pieces (1) with bevels outward and

springs (2) in guide sleeve openings.

36 23 207

2

1

Attach sliding sleeve (1) with the orientation groove (2)to the reverse gear wheel (3).

36 23 208

1

3

2

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Tilt thrust pieces (1) out of the sliding sleeve separatelyfar enough that balls (3) can be placed on the springs.

Push in balls (3) and simultaneously press the thrustpieces into the sliding sleeve. Insert 5th gear

synchronizer ring into the sliding sleeve. Pull thesliding sleeve upwards uniformly as far as the lock

(neutral position).

36 23 209

1

3


Connect needle bearing (1) and 2nd gear wheel (2) tothe output shaft.

Note:Coat needle bearing surfaces with ATF-oil.

36 23 210

1

2

Double taper synchronization:

Note:

On renewal, the 1st/2nd gear synchronization must becompletely renewed.

Attach taper ring (2), friction ring (3) and synchronizerring (4) so that the lugs (5) of the friction ring catch inthe opening (6) on the 2nd gear wheel (1).

Lugs (8) on the synchronizer ring (4) catch in theopening (7).

36 23 167

8

7

62

1

3

4

5

Heat 1st/2nd gear guide sleeve to approx. 120 C (hot airblower) and connect to the output shaft. If necessary,

press on with special tool 23 1 290 until tight.

Caution!

While pressing, ensure that the detent lugs (1) catch inthe opening in the guide sleeve.

36 23 168

1

23 1 290

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Single taper synchronization:Position synchronizer ring (1).

36 23 211

1

Single taper synchronization:Heat 1st/2nd gear guide sleeve to approx. 120 (hot air

blower).

Position the guide sleeve so that the detent lugs (1)

point towards the opening (3) of the guide sleeve (2).

Press guide sleeve (2) with special tool 23 1 290 until

secure.

While pressing, ensure that the detent lugs (1) catch in

the opening in the guide sleeve.

36 23 212

23 1 290

2

1 3

Insert 3 thrust pieces (1) with bevels outward and 3

(pressure) springs (2) in guide sleeve opening.

36 23 207

2

1

Double taper synchronization:Position sliding sleeve (1).

36 23 213

1

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Single taper synchronization:Attach sliding sleeve (1) with the orientation groove (2)

to the 2nd gear wheel. Lug (3) on the sliding sleevepoint towards the middle of the opening (4), or, as the

case may be, the teeth with the grooves (5) towards theopening (6) of the sliding blocks.

36 23 214

1

3

4

5

6

2


Push in balls (3) and simultaneously press the thrust

pieces into the sliding sleeve.

36 23 209

1

3

Insert 1st gear synchronizer ring (1) into the guide

sleeve openings.

Pull the sliding sleeve upwards uniformly as far as the

lock (neutral position).

36 23 235

1

Install appropriate circlip (1). Circlips are available inParts Service from 2.0 ... 2.3 mm in increments of 0.05

mm.

Max. permissible end float X: 0.04 mm.

36 23 170

1

X

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Double taper synchronization:Connect needle bearing (5).

Install synchronizer ring (6), friction ring (4) and taperring.

Position 1st gear wheel.

Caution!Lug (3) must catch in opening (4) and lug (2) must catch

in opening (1).Coat needle bearing and synchronizer ring on bearingsurfaces with ATF-oil.

36 23 171

2

5

1

3

4

6

Single taper synchronization:Connect needle bearing (1).

Position synchronizer ring (2) with the lugs (3) to thesliding blocks.

Note:

Coat needle bearing and synchronizer ring on bearingsurfaces with ATF-oil.

Connect 1st gear wheel (4).

36 23 236

4

1

3

2

Connect roller bearing (1), 5th gear synchronizer ring

(2) and input shaft to the output shaft (3).

Note:


Lift off input and output shafts from special tool23 2 400 and lay to the side.

36 23 237

1

2

3

Layshaft:3rd/4th gear synchronizing device:

For assembly, insert layshaft in special tool 23 2 400.



36 23 137

1

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Hold layshaft in a press.

Select largest possible support surface on fixed wheel.

Remove fixed wheel from the layshaft by pressing.

36 23 138

Remove closing ring (1). For this purpose, bend the 4tabs outwards with pliers for this purpose.

Remove supporting ring (2) (two parts) and stop disc

(3).

Installation:

Replace closing ring (1).

36 23 238

2

1

3

Remove 4th gear wheel (1), synchronizer ring (2) and

needle bearing (3).

36 23 140

3

2

1

Pull 3rd/4th gear sliding sleeve upward.

Caution!Loose thrust pieces, balls and springs.

36 23 217

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Fit countershaft in a press. Press off 3rd gear (1), guidesleeve (2) and bearing bush (3) from the countershaft.

36 23 141

3

2

1

Prior to assembly, check all synchronizing devices forwear.

For this purpose, determine gap measurement X

between synchronizer ring and the correspondinggears.

Measure near the detent lugs.

Uniformly press synchronizer ring in direction of taper.

Gap measurements of the individual gear wheels,refer to Technical Data.

36 23 154

X

Connect needle bearing (1), 3rd gear wheel (3) and

synchronizer ring (2).

Note:


36 23 153

2

3

1

Heat guide sleeve to approx. 120 C (hot air blower) andposition on the layshaft. Position 3rd/4th gear guide

sleeve and press on with special tool 23 1 290 untilsecure.

Caution!While pressing, ensure that the detent lugs (1) catch inthe opening in the guide sleeve.

36 23 155

1

23 1 290

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23/90

Heat inner bearing race (1) to approx. 80 C (hot airblower) and push onto layshaft until limit stop.

36 23 156

1

Insert 3 thrust pieces (1) with bevels outward and 3(pressure) springs (2) in guide sleeve opening.

36 23 239

2

1

Attach sliding sleeve (1) with the orientation groove (2)

to the 3rd gear wheel (3).

The three recessed teeth (4) must point towards the

springs (5) / sliding blocks.

36 23 240

1

2

4

3

5


Push in balls (3) and simultaneously press the thrustpieces into the sliding sleeve. Insert 3rd gearsynchronizer ring into the sliding sleeve. Pull the

sliding sleeve upwards uniformly as far as the lock(neutral position).

36 23 241

1

3

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Connect needle bearing (1), synchronizer ring (2) and4th gear wheel (3) to the layshaft.

Note:


36 23 159

3

1

2

Slip stop disc (1) over the gearing up to the bearingsurface.

36 23 160

1

Insert small radius supporting ring (two parts) (1)

downwards into the groove.

If the supporting ring is replaced, the end float must be

adjusted.Max. end float 0.04 mm.

Supporting rings from 2.9 ... 3.15 mm in increments of0.05 mm are available in Parts Service.

36 23 161

1

Attach special tool 23 2 410 to the layshaft.

Clip the closing ring (1) with 4 fastening lugs into thegroove (3).

36 23 162

3

1

23 2 410

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Heat fixed wheel to approx. 180 C (heating plate).Check with thermometer.



Position layshaft in a press.

Place fixed wheel on the layshaft and press firmly intoplace with special tool 23 1 290.

36 23 163

23 1 290

Insert circlip (1).

36 23 137

1

Connect layshaft together with input and output shafts.

Attach 3rd/4th gear switch rod (1), 1st/2nd gear switchrod (2) and 5th/reverse switch rod (3).

36 23 176

12

3

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Remove clutch release lever and release lever,

refer to 21 51 500

23 21 505 Removing and installing/replacingcomplete input and output shafts(S5D 200G/ E36 M41)


Unscrew oil drain plug.

Drain off transmission oil.

Secure special tool 23 0 100 on the bore of the oil drain

plug.

Fit transmission to assembly frame 00 1 490 with


36 23 100

23 0 100

00 1 490


Unfasten collar nut with special tool 23 1 210.23 1 210

23 0 020

36 23 102

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Pull off output flange.

Note:If ease-of-movement is impaired, remove output flange

with special tool 33 1 150.

36 23 103

33 1 150


36 23 218

00 5 010

Remove cap (1).

36 23 104

1

Remove compression springs (1) and cylinder pins (2).

36 23 105

1

2

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Remove locking stops and ball stops (3) (5 off) withhelp of a magnet (4).

36 23 106

3

4

Note:Note locking pin (1) in the central selector rod!

36 23 107

1

Locking pin (1) on middle selector rod (2) must locate in

centre of selector rod.

Note:

To secure the position of the locking pin (1), thetransmission must be shifted into 2nd gear.

R23 0088

2

1

Shift into 2nd gear:

Insert splint driver or screwdriver (1) in bore of selectorshaft (2).

Twist selector shaft (2) up to 1st left detent and press

into the transmission.

R23 0061

2

1

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Unfasten screws.

R23 0062

Remove sealing ring.

R23 0063

Remove screw (1), reverse gear switch (2).

Lever out cap (3).

36 23 109

1

2

3

Remove spring (4) and arrester bolt (5).

36 23 110

5

4

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Unscrew screws (1 and 2).

36 23 219

1 2

Drive dowel pin (1) out towards clutch case with a cotterpin extractor.

R23 0064

1

Drive out cotter pin (2) with a cotter pin extractor.

R23 0065

2

Unfasten screws on transmission case (9 off).

R23 0066

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23/56

Remove transmission from assembly frame 00 1 490and put down with the output side facing upwards.

Fit special tool 23 1 141 together with 23 1 142 and

23 1 143 and install on rear case section.

Pull off rear case section.

36 23 114

23 1 141

23 1 142

23 1 143

Remove middle selector rod until all 3 selector rods areat the same height.

36 23 196

Remove retaining plate (1) and magnetic disc (2).

36 23 117

1

2

Withdraw pin (3).

Remove pivot lever (4).Remove gearshift rail (6).

Note:There are 4 rollers at the lower end of the selector shaft(5) and these can fall out when the selector shaft is

removed.

Pull out shift shaft (5).

4

5

6

336 23 118

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Place front case section and gear train on special tool23 2 190.

23 2 190

R23 0067


36 23 120

Probe disassembly apertures (1 and 2) on the radial

seal with a scribing tool and push through.

Drive one side of radial seal to limit position (on an

assembly aperture) in the transmission case.In the opposite assembly aperture, insert a self-tapping

screw and use it to remove the radial seal.

36 23 121

1

2


must be inserted on the input shaft during removal ofthe circlip (3).

Lift out circlip (3) and pull off over special tool 23 2 460.

36 23 197

3

23 2 460

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Take off spacer (4).

36 23 198

4

Secure special tool 23 1 141 to front case section with 2screws.

Pull front case section from gears and shafts.

36 23 123

23 1 141

Take off needle bearing (1).

Remove reverse gear (3) with reverse gear pins (2).1

2

3

36 23 128

Remove complete gear train from special tool 23 2 190with selector rods (1)

36 23 130

1

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Reassemble transmission:

Install complete gear train in special tool 23 2 190 withselector rods.

R23 0089

23 2 190

Install reverse gear with collar (2) facing upwards, theninstall and tighten down reverse gear shaft with long

extension (1) in the special tool 23 2 190.

Coat locating face of short extension (3) on reversegear with Loctite 574 gasket compound.


36 23 222

1

3

2

Check end float of the input shaft.

Apply special tool 23 2 420 on the input shaft.

Insert spacer disc (2) and new circlip (1) in the groove.

Check end float with a feeler gauge.

End float 0.04 mm.

Note:Spacer discs (2) can be obtained from Parts Service inthicknesses (X) of 2.3 ... 2.65 mm.

36 23 173

1

23 2 420

X

2

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Heat input shaft inner bearing race (1) in the front casesection to approx. 110 ... 120 C (hot air blower).

Heating temperature must be maintained precisely:

check with a temperature measuring device.



Align selector rods with one another.

After heating, insert the roller bearing (2) with thickgrease into the bearing sleeve with large diameter

facing upwards.

1

2

36 23 223

Carefully attach the front case section.

Note:The 5th gear synchronizer ring can jam.

After completely assembling the transmission, the 5thgear synchronizer ring can be loosened again by

twisting the output/input shafts against each other.

36 23 224

Install spacer (5).

Caution!To avoid damaging input shaft, special tool 23 2 460must be inserted on the input shaft while installing the

circlip (6).

Slide new circlip (6) over special tool 23 2 460 and

install in groove.

36 23 199

6

23 2 460

5

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Coat sealing lip of new radial seal with ATF oil.

Push radial seal (1) over special tool 23 2 460 up tocase.

Remove special tool 23 2 460.

36 23 225

1

23 2 460


Note:Use plastic hammer to drive in.

36 23 226

1

23 2 430

Install guide tube.

Install screws with Loctite 243 screw locking varnish.

Tightening torque,


36 23 120

Secure reverse gear shaft in front case section.

Install screw (1) with Loctite 243 screw locking varnishand tighten.

Tightening torque,


Loosen screw (2) from special tool 23 2 190.

1

36 23 182

2

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Remove front case section and gear train from specialtool 23 2 190 and place to one side with output end

pointing upwards.

23 2 190

R23 0067

Attach 4 rollers to the selector shaft with Vaseline.

36 23 183

Insert selector shaft (1) into front case section.

Insert gearshift rail (2) with the opening upward into thecase.

1

2

36 23 184

Install pivot lever with wider head (1) facing the selectorrod (2).

Ground side of pivot lever must point towards case.

Attach pivot lever with the pin (3).

1

2

336 23 227

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Install locking pin (1) in the selector rod (2) withVaseline and secure in the centre.

36 23 228

21

Place retaining plate (1) with flat side uppermost on 2ndgear on countershaft. Screw special tool 23 2 440 into

the retaining plate (1)

Install magnetic disc (2) in the case. Align selector rodswith one another. Coat locating face of reverse gearshaft (3) with Loctite 574 gasket compound.

Clean case sealing surfaces and coat with Loctite 547

gasket compound.


23 2 440

1

2

3

36 23 229

Lift radial seal on selector shaft out of rear case.

Heat inner bearing race (1) and rear case section in areaaround bearing to 110 ... 120 C (hot air blower).



36 23 230

1

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Fit rear case firmly home on the gear train.

Install 3 screws with new sealing rings. Remove specialtool 23 2 440.

Screw in fourth screw with new sealing ring.

Tighten down all screws.

Tightening torque,


36 23 187

23 2 440

Lightly secure front and rear case sections withopposite two screws.

Place rear case section on support 23 0 100 and again

lift with the assembly hoist 00 1 490.

36 23 100

23 0 100

00 1 490


R23 0064

1


R23 0065

2

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Screw in all case screws and tighten down.


R23 0066

Loosen bolt (1).

Install screw (2) with Loctite 243 locking varnish.

Tighten the screws (1 and 2).


36 23 219

1 2

Install radial seals for selector and output shafts:

Coat sealing lip with ATF-oil.

Push in output shaft radial seal with special tool

24 0 110 and selector shaft radial seal with special tool23 1 240.

Note:Use plastic hammer to drive in.

36 23 188

24 0 110

23 1 240

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Heat output flange to approx. 80 C (hot air blower) andfit to output shaft.

Coat thread and locating face of collar nut (1) with

Loctite 243 locking varnish.


Tighten collar nut (1) with special tool 23 1 210.


36 23 189

23 1 210

23 0 020

1

Install arrester and locking balls.

Order:

Locking ball (1), arrester ball (2) and locking pin (3).

36 23 202

2

1

3

Install springs (1) and cylinder pins (2).

36 23 105

1

2

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Attach cap (1).

Install screws with Loctite 243 screw locking varnishand secure.

36 23 231

1

Install arrester bolt (1) and spring (2).

Note:Roller (3) must be positioned horizontally.

36 23 203

3

1

2

Install shear-off screw (1) with Loctite 243 locking

varnish and tighten down.

Install the reverse gear switch.


Knock in plug (3).

36 23 204

1

2

3

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Unfasten screws and remove retaining plates (1).

R23 0068

1

23 21 706 Replacing bearings on alltransmission shafts (S5D 200G/E36 M41)


Removing input and output shafts,refer to 23 21 505

Bearings on output shaft in rear section ofcase (rear case):

Secure rear case on assembly frame 00 1 490 using


36 23 232

23 0 100

00 1 490

Drive bearings out with special tools 23 1 340 / 00 5 500.

36 23 116

00 5 500

23 1 340

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Heat rear case beside bearings to approx. 80 C (hot airblower).

Install new bearing: if necessary, drive in bearing to

limit position with special tool 23 2 450/ 00 5 500.

36 23 145

00 5 500

23 2 450


Fit retaining plates (1).

Coat screws with Loctite 243 and screw down.


R23 0068

1

Bearings on countershaft:


Note:

Screw (1) has a left-hand thread.

Unscrew bolt (1).

R23 0069

1

Press off bearing (2) with special tool 23 1 250 on ahydraulic press.

R23 0070

2

23 1 250

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Press off inner bearing race (3) with special tool00 7 500 / 23 1 250 on a hydraulic press.

R23 0071

23 1 25000 7 500

3

Note:Taper (2) on outer bearing race must point upwards.

Press on new bearing (1) with special tool 23 1 040 on a

hydraulic press.

R23 0072

1

2

23 1 040


Tighten in new screw (1) and tighten down.

Tightening torque,


R23 0069

1

Output shaft bearing in front section of case:

Unfasten screws and remove retaining plates (1).

R23 0073

1

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Drive out bearing with special tool 23 1 340 / 00 5 500.

36 23 125

00 5 50023 1 340

Heat the front case section in the area near the bearingto approximately 80 C (hot air blower).

Install new bearing and, if necessary, drive in bearing to

limit position with special tool 23 1 450 / 00 5 500.

R23 0074

00 5 500

23 2 450


Fit retaining plates (1).

Coat screws with Loctite 243 screw locking varnish and

screw in.

Tightening torque,


R23 0073

1

Outer bearing race of countershaft in frontcase section:

Install special tool 23 1 280 in the outer bearing race (1).

36 23 126

1

23 1 280

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Apply special tool 33 4 020.

Screw special tool 23 1 300 on to 23 1 280.


36 23 127

23 1 30033 4 020

Install new bearing shell (1) with recess on bearingshell aligned with the locking device (2) in the case.

34 23 213 U

12

Drive bearing shell (1) into limit position with special

tool 23 1 260 / 00 5 500.

36 23 147

12

23 1 260

00 5 500

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Dismantling input and output shafts:

Place complete input shaft (1) and output shaft (2) onspecial tool 23 2 190.

R23 0075

23 2 190

1

2

23 23 508 Dismantling and assembling allsynchronizer units (S5D 200G/ E36M41)


Completely remove and install input and output shafts,refer to 23 21 505.

Remove selector rods (1) from gear train.

Remove countershaft from input and output shafts.

36 23 130

1

Remove input shaft (1) from the output shaft.

R23 0076

1

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Remove roller bearing (1) and synchronizer ring for 5thgear (2).

R23 0077

2

1


Note:When removing the sliding sleeve, pressure pieces,

balls and springs drop out.

Sliding sleeve for 5th/Reverse Remove gear (2) from

guide sleeve.

36 23 205

2

1

Place output shaft (1) with output end upwards on


R23 0078

23 2 190

1

Remove gear from 1st gear (1) and needle bearing (2).

Remove synchronizer ring (3), taper ring (4) and frictionring (5).

36 23 132

1

2

35

4

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Note:When removing the sliding sleeve, pressure pieces,


Remove sliding sleeve for 1st/2nd gear (2).

36 23 133

1

2

Note:Gear on 2nd gear (2) must lie face down and flush with

surface of hydraulic press.

Press guide sleeve (1) off the output shaft and remove.

36 23 134

1

2

Remove synchronizer ring for 2nd gear (2).

R23 0079

2

Remove friction ring (3).

R23 0080

3

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Remove taper ring (4).

R23 0081

4

Remove gear from 2nd gear (5) and needle bearing (6)from the output shaft.

R23 0082

5

6

Press guide sleeve (1) on 1st/Reverse gears off output

shaft and remove using special tool 23 1 490 andhydraulic press.

36 23 136

23 1 490

1

R

Remove synchronizer ring (2), reverse gear (3) andneedle bearing (4) from the output shaft.

R23 0083

2

3

4

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Check all synchronizer units for wear. For this purpose,determine gap measurement X between synchronizer

ring and the corresponding gears.

Measure near the detent lugs. Uniformly presssynchronizer ring in direction of taper.

Gap measurements of the individual gear wheels,refer to Technical Data.

Note:If the gap dimension (x) is too tight, synchronizer ring,

friction ring and taper ring must be replaced.

36 23 154

X

Assemble output shaft:

Note:Apply light coat of ATF oil to needle bearing (1) and

synchronizer ring (2) to the bearing races.Fit needle bearing (1), reverse gear (3) and synchronizer

ring (2) to the output shaft.

36 23 164

1

3

2

Caution!When press-fitting the guide sleeve, ensure that the

detent lugs (2) of the synchronizer ringes engage in therecesses in the guide sleeve.

Heat guide sleeve for 5th/Reverse gears (1) to approx.120 C (hot air blower) and fit on output shaft, ifnecessary pressing firmly home using special tool

23 1 290.

36 23 165

23 1 290

2

1

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Install new retaining ring (1) and determine end float (X)with a feeler gauge.

Permitted end float (X) max. 0.04 mm.

Note:Circlips are available in Parts Service from 2.0 ... 2.3 mm

in increments of 0.05 mm.

36 23 166

1

X

Insert a pressure piece (1) with a spring (2) in therecesses of the guide sleeve.

Note:

Tapers on the pressure piece point downwards.

36 23 207

2

1

Push sliding sleeve (1) towards reverse gear (3) with

designation groove (2) facing gear.

36 23 208

1

3

2

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Install ball stops (3 off):

Tilt pressure piece (1) out of sliding sleeve until ballstop (3) can be fitted to the compression spring.

Press ball stop (3) into pressure piece (1) and, at thesame time, push pressure piece (1) into sliding sleeve.

After installing the 3 ball stops, insert synchronizer ringfor 5th gear in the guide sleeve.

Press synchronizer ring onto the guide sleeve and pullsliding sleeve uniformly upwards as far as stop (neutral

position).

36 23 209

1

3


Note:Coat needle bearing and races with ATF oil.

Place needle bearing (1) and 2nd gear (2) on the outputshaft.

36 23 210

1

2

Fit taper ring (4) on the 2nd gear.

R23 0081

4

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Fit friction ring (3) on the taper ring.

Note:Friction ring (3) must locate positively in the gear.

R23 0080

3

Place synchronizer ring (2) on the friction ring.

Note:The synchronizer ring (2) must locate positively in the

taper ring.

R23 0079

2

Caution!

When press-fitting the guide sleeve, ensure that detentlugs (1) on the synchronizer ring locate in the recess ofthe guide sleeve.

Heat guide sleeve on 1st/2nd gear to approx. 120 C (hotair blower) and fit on output shaft, pressing firmly down

if necessary with special tool 23 1 290.

36 23 168

1

23 1 290

Fit one pressure piece (1) with a spring (2) in eachrecess of the guide sleeve.

Note:Tapers on the pressure piece point outwards.

36 23 207

2

1

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Fit sliding sleeve (1) with designation groove facing 2ndgear (2).

R23 0084

1

2


Tilt pressure piece (1) out of sliding sleeve until the ballstop (3) can be fitted to the compression spring.

Press ball stop (3) into the pressure piece (1) and, at thesame time, push the pressure piece (1) into the sliding

sleeve.

36 23 209

1

3

Insert synchronizer ring for 1st gear (1) into the guide

sleeve.

Press synchronizer ring onto the guide sleeve and pull

sliding sleeve firmly upwards as far as stop (neutralsetting).

36 23 235

1

Install new circlip (1) and measure end float (X) with afeeler gauge.

Permitted end float (X) max. 0.04 mm.

Note:Circlips are available in Parts Service from 2.0 ... 2.3 mmin increments of 0.05 mm.

36 23 170

1

X

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Fit needle bearing (5) onto the output shaft.

Install synchronizer ring (6), friction ring (4) and taperring (3) in the guide sleeve.

Note:Lug (3) on taper ring must locate in recess (4) of

synchronizer ring.

Fit 1st gear.

Note:Lug (2) on friction ring must locate in recess (1) in gear.

36 23 171

2

5

1

3

4

6

Note:


Fit roller bearing (1), 5th gear synchronizer ring (2) andinput shaft (3) onto the output shaft.

Remove input and output shafts from special tool23 2 190 and place to one side.

36 23 237

1

2

3

Dismantling countershaft:

Install countershaft (1) in special tool 23 2 190.

R23 0085

23 2 190

1

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36 23 137

1

Note:Select largest possible locating face on gear.

Press gear off the countershaft.

36 23 138

Bend 4 retaining lugs on locking ring (1).

Remove locking ring (1) from thrust washer (2).

Remove thrust washer (2) (two halves) and thrust

washer (3) from the countershaft.

36 23 238

2

1

3

Remove 4th gear (1), synchronizer ring (2) and needlebearing (3) from the countershaft.

36 23 140

3

2

1

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Note:When removing the sliding sleeve, the pressure pieces,


Pull 3rd/4th gear sliding sleeve upward.

36 23 217

Press 3rd gear (1), guide sleeve (2) and bearing bush (3)off the countershaft.

36 23 141

3

2

1

Remove needle bearing (4).

R23 0086

4

Check synchronizer unit for signs of wear.

For this purpose, determine gap measurement Xbetween synchronizer ring and the correspondinggears.

Measure near the detent lugs.

Uniformly press synchronizer ring in direction of taper.

Gap measurements of the individual gear wheels,

refer to Technical Data.

36 23 154

X

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Assemble countershaft:

Note:Coat needle bearing and synchronizer ring on bearing

surfaces with ATF-oil.

Fit needle bearing (1), 3rd gear (3) and synchronizer

ring (2) to the countershaft.

36 23 153

2

3

1

Caution!When press-fitting the guide sleeve, ensure that the

detent lugs (1) on the synchronizer ring locate in theguide sleeve recess.

Heat guide sleeve for 3rd/4th gears to approx. 120 C(hot air blower), fit on countershaft and press firmly

home with special tool 23 1 290.

36 23 155

1

23 1 290

Heat inner bearing race (1) to approx. 80 C (hot air

blower) and push onto layshaft until limit stop.

36 23 156

1

Place one pressure piece (1) with a spring (2) in eachrecess in the guide sleeve.

Note:Tapers on the pressure piece point outwards.

36 23 239

2

1

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Fit sliding sleeve (1) with designation groove (2) facing3rd gear (3).

36 23 240

1

2

4

3

5


Tilt pressure piece (1) out of sliding sleeve until the ballstop (3) can just be fitted to the compression spring.

Press ball stop (3) into pressure piece (1) and, at thesame time, push the pressure piece (1) into the sliding

sleeve.

36 23 241

1

3

Insert synchronizer ring for 3rd gear (1) into the guide

sleeve.

Press synchronizer ring into the guide sleeve and

evenly pull sliding sleeve upwards to its limit position(neutral position).

R23 0087

1

Note:Coat needle bearing and synchronizer ring on bearing

surfaces with ATF-oil.

Fit needle bearing (1), synchronizer ring (2) and 4th

gear (3) to the countershaft.

36 23 159

3

1

2

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Slip stop disc (1) over the gearing up to the bearingsurface.

Note:

The Parts No. points upwards.

36 23 160

1

Install thrust washer (two halves) with the smalldiameter (1) facing downwards between thrust washer

and gear.

Note:If the supporting ring is replaced, the end float must beadjusted.

Max. end float 0.04 mm.

Supporting rings from 2.9 ... 3.15 mm in increments of0.05 mm are available in Parts Service.

Split new thrust washer at the nominal breakage point.

36 23 161

1

Fit special tool 23 2 390 onto the countershaft.

Fit locking ring (1) onto thrust washer with special tool23 2 390. The 4 locating lugs must engage in the groove(3) of the locking ring.

R23 0090

3

1

23 2 390

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Heat gear to approx. 180 C (heating plate). Check withthermometer.



Fit gear to countershaft and press down to limit

position using special tool 23 1 290 and a hydraulicpress.

36 23 163

23 1 290

Install new circlip (1).

36 23 137

1

Fit countershaft with input and output shafts.

Fit selector rod 3rd/4th gear (1) , selector rod 1st/2ndgear (2) and selector rod 5th/Reverse gear (3) to the

gear train.

36 23 176

12

3

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Lever out radial sealing ring for the output flange.

Installation:Replace radial sealing ring.

34 23 200 U

23 21 805 Replace the bearings of alltransmission shafts (S5D 260Z/310Z)

Note:Input and output shafts removed

Rear Case Section:

Unscrew bolts.

Remove retaining plates (1 and 2).

34 23 199 U

1

2

Drive out the ball bearing for the output shaft towardthe inside, using Special Tool 23 1 440.

34 23 201 U

23 1 440

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Layshaft:

Heat case in area of the ball bearing to about 80 C witha hot air blower.

Remove ball bearing (1) toward the inside.

Clean the rear case section to remove dirt.

34 23 202 U

1

Heat rear case section in area of the ball bearinguniformly to about 80 C with a hot air blower.

Install ball bearings for output shaft and layshaft.

Insert ball bearing (1) for the layshaft with theshouldered end (1) facing in.

34 23 203 U

1

1

If necessary, drive in ball bearings to fit tight.

Output shaft, Special Tool 23 1 470, countershaft,Special Tool 23 1 220 in conjunction with Special Tool

00 5 500 (handle)

34 23 204 U

00 5 500

23 1 220

23 1 470

Install retaining plates.

Insert and secure screws with screw retaining agent(refer to BMW Parts Service).

Tightening torque,


34 23 205 U

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In order to replace the inner bearing race (2), the 3rd/4thgear wheel must be pressed off using tool 23 2 310.

Removal, refer to Replacing the synchronizing device

3rd/4th gear,refer to 23 23 507.

R23 0034

2

23 2 310

Bearings in Front Case Section:

Input Shaft:

Unscrew bolts.

Remove retaining plates (1).

34 23 207 U

1

Heat case in area of the ball bearing to about 80 C with

a hot air blower.

Pull out ball bearing (2); if necessary drive it out from

outside to inside with help of Special Tool 23 1 440.

34 23 208 U

2

Heat case in area of the ball bearing to about 80 C witha hot air blower.

Install ball bearing (2); if necessray drive it in to fit tightwith Special Tool 23 1 470.

34 23 209 U

2

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Insert retaining plates (1).

Insert and secure screws with screw retaining agent(refer to BMW Parts Service).


34 23 210 U

1

Layshaft:

Bearing shell (1) for needle bearing. Place Special Tool23 1 280 in bearing shell (1).

34 23 211 U

1

23 1 280

Apply Special Tool 33 4 020.

Screw on Special Tool 23 1 300.


34 23 212 U

33 4 020

23 1 300

Installation:Insert bearing shell (1) so that the slot in the bearing

shell is aligned with beads (2) (turning lock) in the case.

34 23 213 U

12

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Drive in bearing shell (1) with Special Tool 23 1 260 inconjunction with Special Tool 00 5 500 (handle).

34 23 214 U

00 5 500

23 1 260

1

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Loosen the screws and pull off the guide pipe.

34 23 104 U

23 21 502 Remove and install the input andoutput shafts (S5D 260Z/ 310Z)

Remove the transmission (depending on model),refer to 23 00 023.

Remove the clutch operator / lever,refer to 21 51 500.

Unscrew drain plug.

Drain oil.

Screw Special Tool 23 0 100 (transmission support)

into bore of drain plug and secure.

Locate Special Tool 23 0 100 (support) in Special Tool

00 1 490 (assembly frame).

34 23 107 U23 0 100

00 1 490

Locate and puncture bores (1 and 2) with a markingtool.

Drive in radial sealing ring on one end as far as it willgo. Screw a suitable self-tapping screw in the opposite

bore.

Pull out radial sealing ring on the self-tapping screw

using pliers.

34 23 108 U

1

2

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Caution!Special Tool 23 2 380 must be used on the input shaft to

remove circlip (3) so that the input shaft is notdamaged.

Lift out circlip (3) and pull off over Special Tool23 2 380.

Take off spacer (4).


3

34 23 224 U

23 2 380 4

Unscrew left bearing shaft bolt and reverse gear shaft

bolt in the front case section.

34 23 110 U

Unscrew reverse gear switch and right bearing shaftbolt in the front case section.

34 23 111 U

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Remove sealing cap (2).

34 23 112 U

1

2

Lift out spring

Documents

Rep_S5D