Rep S5D

23/2
23 00 022 Removing and installing transmission (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 the expansion tank on the master brake cylinder can become 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 flange and tie up to one side, refer to 26 11 000.
Remove retainer (1).
2 3 1
Withdraw selector rod (3) from selector linkage joint and remove washers (2).
Installation: Apply thin coat of grease to selector rod. Grease, refer to BMW Service Operating Fluids.
36 25 018 E
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
23/3
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.
00 0 200
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).
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 bracket of crankcase. Fit special tool 00 0 200 and attach to special tool 11 0 030.
00 0 200
11 0 030
Tighten spindle (2).
1
36 23 024 U
23/4
M41/M43 engine: Attach special tool 11 8 022 to left and right control arms.
11 8 022
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.
36 23 028 E
Support transmission with a workshop hoist. Unfasten screws and remove cross member with rubber 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) until cylinder head and manifold are just above, but not in contact with, engine fire wall or heating connections (visual check).
00 0 200
11 0 030
1
36 23 024 U
M41/M43 engine:
11 8 022
Lower engine and transmission by unfastening knurled screws 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
23/5
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. Grease, refer to BMW Service Operating Fluids.
1 2
36 25 024 U
Support transmission with workshop hoist. Unfasten screws.
Caution! Do not allow transmission to hang on transmission input shaft when removing and installing, as the clutch disc will be deformed.
Pull transmission downwards and remove.
M
B
Installation: Always fit screws with washers. Tightening torque, refer to Technical Data 23 00 1AZ.
32 23 010 E
1 2
Installation: Note dowel sleeves (1 ... 2) and replace if necessary. Ensure correct position of cover plate.
34 23 011 E
Installation: Remove release unit and release lever and apply grease to appropriate points, refer to 21 51 500.
23/6
Installation: Check lubrication of transmission input shaft for sticky consistency. If the grease is sticky, the clutch disc must be 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 abrasion from the taper splines of the clutch disc (with a cloth). Clean spline grooves and guide spigots on transmission input shaft and apply a thin coat of grease.
32 23 043 E
The volume of grease required for this corresponds roughly to the size of a corn on the cob. Grease, refer to BMW Service Operating Fluids.
23/7
23 00 023 Removing and installing transmission (S5D 260Z, S5D 310Z)
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 the expansion tank on the master brake cylinder can become 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 flange and tie up to one side, refer to 26 11 000.
Remove retainer (1).
2 3 1
Withdraw selector rod (3) from selector linkage joint and remove washers (2).
Installation: Apply thin coat of grease to selector rod. Grease, refer to BMW Service Operating Fluids.
36 25 018 E
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
23/8
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 tool 11 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.
00 0 200
11 0 030
Tighten spindle (2).
1
36 23 024 U
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 special tool 11 2 370. Tighten spindle.
23/9
S50 engine: Attach special tool 11 8 022 to left and right control arms.
11 8 022
36 23 028 E
Support transmission with a workshop hoist. Unfasten screws and remove cross member with rubber 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) until cylinder head and manifold are just above, but not in contact with, engine fire wall or heating connections (visual check).
00 0 200
11 0 030
1
36 23 024 U
S50 engine:
11 8 022
Lower engine and transmission by unfastening knurled screws 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
23/10
S50 engine:
11 8 021
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 after removing transmission.)
36 23 030 E
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. Grease, refer to BMW Service Operating Fluids.
1 2
36 25 024 U
Support transmission with a workshop hoist. Unfasten screws.
M
B
Installation: Always fit screws with washers. Tightening torque, refer to Technical Data 23 00 1AZ.
32 23 010 E
1 2
34 23 011 E
23/11
Installation: Remove and clean release unit and release lever and grease appropriate points, refer to 21 51 500.
Installation: Check lubrication of transmission input shaft for sticky consistency. If the grease is sticky, the clutch disc must be 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 abrasion from taper splines of clutch disc (with a cloth). Clean spline grooves and guide spigots on transmission input shaft and apply a thin coat of grease.
32 23 043 E
The volume of grease required for this corresponds roughly to the size of a corn on the cob. Grease, refer to BMW Service Operating Fluids.
23/12
23 00 025 Removing and installing transmission (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 Diagnosis System. 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/or 0 to E until the transmission stops performing gear changes.
R23 0092
Note: The gear display on the instrument cluster starts to flash and/or the engaged driving range ceases to be
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.
Open expansion tank (1) and reservoir (2) and draw hydraulic fluid out of both containers.
R21 0043
23/13
4 3 1 2
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 5 010 and 17 0 002. Close bleed screw (3). Fill expansion tank (1) up to MAX mark (dipstick (4) on cover).
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
Remove heat shield (1). Remove heat shield from right transmission crossmember.
1
36 26 010 U
23/14
3
Remove brackets (1... 2) for exhaust suspension (only if fitted). Remove reinforcement (3).
Installation: Remove reinforcement (3) with long collar (4) facing forwards.
2 4
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 to torsion 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) Tightening Torque, refer to Technical Data 26 11 6AZ.
23/15
Caution! Do not let propeller shaft fall into joints. In particular, on the constant velocity joint, the rubber sleeve gets squashed or the joint is damaged.
Bend the propeller shaft downwards from the centre bearing, remove from the transmission output flange and secure to the side of the underbody with a piece of string or wire.
31 26 014 E
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
Pull cable connector (1) off reverse gear switch.
R23 0093
23/16
Pull cable connector (1) off cable on speed sensor.
1
R23 0095
Pull cable connector (1) off transmission oil temperature sensor.
R23 0098
Unfasten cable connector (1) (switch for gear recognition) from the bracket and disconnect.
1
R23 0099
Unfasten and disconnect cable connector (1) on Lambda oxygen sensor bracket. Unfasten cable from bracket on transmission cross member.
1
R23 0097
23/17
Loosen nut (1). Pull retaining clip (2) off and remove cable (3) from bracket (4).
4 3 1 2
R23 0100
Installation: Adjust cable, refer to 25 16 ... .
Pull off retaining clip (1) and cable (2) from bracket (3).
2
R23 0101
Unfasten screws and remove transverse tube (1).
Installation: Tightening Torque, refer to Technical Data 41 11 1AZ.
1
R23 0102
Disconnect hydraulic lines (1... 3) and seal with suitable plastic plugs.
1 2 3
Unscrew holder (4).
Installation: Tightening Torque, refer to Technical Data 21 52 1AZ.
R23 0103
23/18
Support transmission with special tool 00 2 030 / 23 0 040 / 23 0 042.
23 0 040 00 2 030
23 0 042
R23 0104
Caution! Do not support or lift transmission from switch for gear recognition (1).
R23 0118
Release screws Only lower transmission until cylinder head and manifold 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
Attach special tool 11 8 022 to left and right control arms.
11 8 022
36 23 028 E
23/19
Secure special tool 11 8 021 to front axle support.
11 8 021
Turn screw (1) upwards until it is flush with the oil pan.
Note: This support prevents the engine from tilting forwards while the transmission is being removed.
36 23 030 E
Release screws
M
B
32 23 010 E
Installation: Always fit screws (1) with narrow collar using shims. Fit screws (2) with wide collar without any shims. Tightening Torque, refer to Technical Data 23 00 1AZ.
R23 0117
1 2
34 23 011 E
23/20
Installation: Remove and clean release unit and release lever and grease appropriate points, refer to 21 51 500.
Installation: Check lubrication of transmission input shaft for sticky consistency. If the grease is sticky, the clutch disc must be 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 abrasion from taper splines of clutch disc (with a cloth). Clean spline grooves and guide spigots on transmission input shaft and apply a thin coat of grease.
32 23 043 E
The volume of grease required for this corresponds roughly to the size of a grain of maize. Grease, refer to BMW Service Operating Fluids.
23/21
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 new transmission, refer to 21 51 500.
Transfer shift-rod joint. Slide back retaining sleeve or retaining ring (1).
2 1
Drive out cylindrical pin (2).
31 23 030 U
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.
23/22
23 00 033 Installing replacement transmission (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).
1 3
Remove breather (1) and protective sleeve (2) from selector shaft. Lift off sealing cap (3) and install breather (1).
2
36 23 013 U
Installing release unit and release lever in the new transmission, refer to 21 51 500.
Transfer shift-rod joint. Slide back retaining sleeve or retaining ring (1).
2 1
Drive out cylindrical pin (2).
31 23 030 U
23/23
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.
23/24
23 12 055 Replacing radial seal for output flange (S5D 260Z/ 310Z)
After completion of work, check transmission oil level, refer to 00 11 229. Disconnect propeller shaft from transmission flange and tie up to one side, refer to 26 11 000.
Support transmission with a workshop hoist. Unfasten screws and remove cross-member.
Installation: Tightening torque, refer to Technical Data 23 71 1AZ/ 2AZ.
36 23 011 U
Brace output flange with special tool 23 0 020.
23 2 320
Unfasten collar nut (1) with special tool 23 2 320.
Installation: Install collar nut (1) with screw retainer: for screw retaining compound, refer to BMW Parts Service. Tightening torque, refer to Technical Data 23 21 1AZ.
23 0 020
34 23 124 U
Remove output flange from transmission output shaft with special tool 33 1 150.
33 1 150
Installation: Heat output flange to approx. 80 C and slide onto transmission output shaft.
36 23 103
23/25
Remove radial seal with special tool 00 5 010.
00 5 010
36 23 022 U
Coat sealing lips of new radial seal (3) with transmission oil.
23 2 300
Drive radial seal (3) home flush with special tool 23 2 300.
Note: Use plastic hammer to drive in.
34 23 135 U
23/26
23 12 056 Replacing radial seal for output flange (S5D 200G/ 250G)
After completion of work, check transmission oil level, refer to 00 11 229. Disconnect propeller shaft from transmission flange and tie up to one side, refer to 26 11 000.
If necessary, lift out retaining plate (1).
Installation note: Do not fit retaining plate.
36 23 101

23 1 210
Unfasten collar nut with special tool 23 1 210.
23 0 020
Installation note: Install collar nut with screw retaining compound: for screw retainer refer to BMW Parts Service. Tightening torque, refer to Technical Data 23 21 1AZ.
36 23 102
Remove output flange from transmission output shaft with special tool 33 1 150.
33 1 150
36 23 103
23/27
00 5 010
36 23 022 U
Coat sealing lips of new radial seal with transmission oil. Drive in radial seal flush with special tool 24 0 110.
24 0 110
36 23 023 U
23/28
23 12 085 Replacing radial seal on selector shaft (S5D 260Z/310Z)
Unflange propeller shaft from transmission and tie up to one side, refer to 26 11 000
2 1
Push back locking sleeve (1) and drive out cylindrical pin (2).
36 23 018 U
Pry out radial sealing ring (3) with a narrow screwdriver.
36 23 019 U
Drive in radial seal (1) with special tool 23 2 260.
1
23 2 260
34 23 147 U
23/29
23 12 086 Replacing radial seal on selector shaft (S5D 200G/250G)
Unflange propeller shaft from transmission and tie up to one side, refer to 26 11 000
2 1
Push back locking sleeve (1) and drive out cylindrical pin (2).
36 23 018 U
Pry out radial sealing ring (3) with a narrow screwdriver.
36 23 019 U
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
23/30
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, refer to Technical Data 23 11 2AZ.
34 23 104 U
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
Coat sealing lips of new radial seal with transmission oil. Drive in radial seal (1) flush using special tool 23 2 340.
Caution! Use a plastic hammer for driving in seal.
23 2 340
34 23 221 U
23/31
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. Tightening torque, refer to Technical Data 23 11 2AZ.
36 23 242
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
Fit special tool 23 2 460 to the transmission input shaft. Coat sealing lips of new radial seal (1) with transmission oil and slide firmly home on transmission case.
23 2 460
Remove special tool 23 2 460 from the transmission input shaft.
36 23 220
23/32
Drive radial seal (1) firmly home with special tool 23 2 430.
23 2 430
36 23 221
23/1
23 .. ... For other operations on transmission, refer to microfiche of Construction Group Repair Manual
23/33
23 21 505 Complete removal and installation of 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.
00 1 490
23 0 100
36 23 100
Remove clutch release unit and release lever, refer to 21 51 500
When fitted: Lift out lockplate (1).
36 23 101
23/34
23 1 210
23 0 020
36 23 102
Pull off output flange.
33 1 150
Note: If output flange has ease-of-movement with special tool 33 1 150.
36 23 103
00 5 010
36 23 218
Remove cap (1).
36 23 104
23/35
Remove compression springs (1) and cylinder pins (2).
36 23 105
Remove locking and ball stops (3) (5 off) with the help of a magnet (4).
36 23 106
Note: Note locking pin (1) in the centre selector rod!
36 23 107
Locking pin (1) on centre selector rod (2) must be located in centre of selector rod.
2 1
Note: To secure position of locking pin (1), transmission must be shifted into 2nd gear.
R23 0088
23/36
Shift into 2nd gear:
1 2
Insert cotter pin extractor or screwdriver (1) in the bore of the selector shaft (2). Turn selector shaft (2) to 1st detent anticlockwise and press into the transmission.
R23 0061
Unfasten screws.
R23 0062
Remove sealing ring.
R23 0063
Unfasten screw (1) and reverse gear switch (2). Lever out cap (3).
1 3 2
36 23 109
23/37
Remove spring (4) and arrester bolt (5).
4
36 23 110
Unscrew screws (1 and 2).
36 23 219
Drive cotter pin (1) towards clutch housing with a cotter pin extractor.
R23 0064
Drive out cotter pin (2) with a cotter pin extractor.
R23 0065
23/38
Unfasten screws on transmission case (9 off).
R23 0066
23 1 141
Remove transmission from assembly frame 00 1 490 and 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.
23 1 142
Pull off rear case section.
23 1 143
36 23 114
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).
2
36 23 117
23/39
Withdraw pin (3).
6 5
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).
36 23 118
Position gears and shafts with front case section on special tool 23 2 400.
23 2 400
36 23 119
36 23 120
Probe assembly apertures (1 and 2) with a scribing tool and 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 the assembly aperture and remove the radial seal on the self-tapping screw.
1
36 23 121
23/40
23 2 460
Caution! To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft during removal of the circlip (3). Lift out circlip (3) and pull off over special tool 23 2 460.
36 23 197
Remove closing ring (4).
36 23 198
23 2 460
Caution! To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft during removal of the 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 input shaft.
6 5
Lift out spacer disc (5).
36 23 199
23/41
Secure special tool 23 1 141 to front case section with 2 screws. Pull front case section from gears and shafts.
23 1 141
36 23 123
Take off needle bearing (1).
Remove reverse gear (3) with reverse gear shaft (2).
3
36 23 128
Remove complete gear train with selector rods (1) from special tool 23 2 400.
1
36 23 130
Reassemble transmission:
Install complete gear train with selector rods in the special tool 23 2 400.
23 2 400
36 23 177
23/42
3 2
Install reverse gear with collar (2) facing upwards and reverse gear shaft with long extension (1) in special tool 23 2 400. Coat short extension (3) of reverse gear shaft and coat locating face with Loctite 574 liquid gasket. Liquid gasket, see BMW Parts Service.
1
36 23 222
Check end float of the input shaft.
1
23 2 420
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.
X 2
36 23 173
Note: Spacer disc (2) is available in thicknesses (X) of 2.3 ... 2.65 mm in Parts Service.
23/43
2
Heat input shaft inner bearing race (1) in the front case section 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 thick grease into the bearing sleeve with large diameter facing upwards.
36 23 223
Carefully attach the front case section.
Note: The 5th gear synchronizer ring can jam. After completely assembling the transmission, the 5th gear synchronizer ring can be loosened again by twisting the output/input shafts against each other.
36 23 224
Install spacer (5).
23 2 460
6 5
Caution! To avoid damaging input shaft, special tool 23 2 460 must 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
23/44
Install closing ring (4).
23 2 460
3 4
Caution! To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft while installing the circlip (3). Slide new circlip (3) over the special tool 23 2 460 and install in the upper groove.
36 23 243
Coat the radial seal sealing lip with ATF-oil. Push radial seal (1) over special tool 23 2 460 up to case.
23 2 460
Remove special tool 23 2 460.
36 23 225

23 2 430
Use plastic hammer to drive in.
1
36 23 226
Install guide tube. Install screws with Loctite 243 screw locking varnish. Screw retaining compound, refer to BMW Parts Service. Tightening torque, refer to Technical Data 23 11 2AZ.
36 23 120
23/45
Secure reverse gear shaft on front case section.
Install screw (1) with Loctite 243 screw locking varnish and tighten. Screw retaining compound, refer to BMW Parts Service. Tightening torque, refer to Technical Data 23 11 6AZ.
Loosen screw (2) from special tool 23 2 400.
36 23 182
Remove front case section and gear train from special tool 23 2 400 and place to one side with output end uppermost.
23 2 400
36 23 201
Attach 4 rollers to the selector shaft with Vaseline.
36 23 183
Insert selector shaft (1) into front case section.
2 1
Insert gearshift rail (2) with the opening upward into the case.
36 23 184
23/46
2
Install pivot lever with the broader head (1) facing the selector rod (2). Polished side must face towards case. Attach pivot lever with the pin (3).
36 23 227
Install locking pin (1) in the selector rod (2) with Vaseline and secure in centre.
36 23 228
Clean case sealing surfaces and coat with Loctite 547 gasket compound.
23 2 440
Place retaining plate (1) on 2nd gear of countershaft with flat side facing upwards. Screw special tool 23 2 440 into the retaining plate (1) Place magnetic disc (2) in the case. Align selector rods with one another. Coat reverse gear shaft (3) on the locating face with Loctite 574 liquid gasket compound. Gasket compound, refer to BMW Parts Service.
1 2
36 23 229
23/47
Lift out radial seal of selector shaft from the rear case. Heat inner bearing race (1) and rear case section in area around bearing to 110 ... 120 C (hot air blower). The heating temperature must be precisely maintained.
Check with a thermometer.
36 23 230
Insert rear case section up to limit stop. Install 3 screws with new sealing rings. Remove special tool 23 2 440.
23 2 440
Screw in fourth screw with new sealing ring. Tighten down all screws. Tightening torque, refer to Technical Data 23 11 17AZ.
36 23 187
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.
00 1 490
23 0 100
36 23 100
Drive in cotter pin (1).
R23 0064
23/48
R23 0065
Screw in all case screws and tighten down. Tightening torque, refer to Technical Data 23 11 1AZ.
36 23 111
Loosen bolt (1). Install screw (2) with Loctite 243 locking varnish. Tighten the screws (1 and 2). Tightening torque, refer to Technical Data 23 11 6AZ.
36 23 219
Install radial seal for selector shaft and output shaft.

24 0 110
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 tool 23 1 240.
Note: Use a plastic hammer for driving in seal.
23 1 240
36 23 188
23/49
Heat output flange to approx. 80 C (hot air blower) and fit on output shaft.
23 1 210 23 0 020
Coat thread and locating face of collar nut (1) with Loctite 243 locking varnish. Brace output flange with special tool 23 0 020. Tighten collar nut (1) with special tool 23 1 210. Tightening torque, refer to Technical Data 23 21 1AZ.
36 23 189
Install arrester and locking balls. Order: Locking ball (1), arrester ball (2) and locking pin (3).
2 1 3
36 23 202
Install springs (1) and cylinder pins (2).
36 23 105
23/50
Attach cap (1). Install screws with Loctite 243 screw locking varnish and secure.
36 23 231
Install arrester bolt (1) and spring (2).
1 2
Note: Roller (3) must be positioned horizontally.
3
36 23 203
Install shear-off screw (1) with Loctite 243 locking varnish and tighten down. Install the reverse gear switch.
1 3 2
Tightening torque, refer to Technical Data 61 31 3AZ. Knock in plug (3).
36 23 204
Install clutch release mechanism and release lever, refer to 21 51 500
23/68
23 21 706 Replacing bearings on all gearshafts (S5D 200G/ 250G)
Transmission removed. Removing input and output shafts, refer to 23 21 505
Output shaft bearings in rear case:

00 1 490
Place rear case section on support 23 0 100 and lift with assembly hoist 00 1 490.
23 0 100
36 23 232
Unfasten screws. If installed, remove oil deflector plate (1). Remove retaining plate (2).
1
36 23 146
00 5 500 23 1 340
Remove output shaft bearing with special tool 23 1 340 and handle 00 5 500 from the outside to the inside.
36 23 116
23/69
00 5 500
Heat the rear case section in the area near the output shaft bearing to approx. 80 C (hot air blower). Install bearing, using, if necessary, special tool 23 2 450 and handle 00 5 500 until securely driven into place.
23 2 450
36 23 145
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, refer to Technical Data 23 11 17AZ.
1
36 23 146
Bearing on the countershaft:
1 3 2
- 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).
36 23 142
Note: Instead of the hex screw (1) and the washer (2), a Torx screw is fitted!
23/70
- Torx screw -
Clamp countershaft in a vise with protective jaws.

Unscrew bolt (1).
R23 0069
23 1 250
Press bearing (2) off countershaft with a special tool 23 1 250 on a hydraulic press.
R23 0070
00 7 500
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 1 040
Note: The taper (2) on the outer bearing race must point upwards.
2 1
Press new bearing (1) off countershaft with special tool 23 1 040 on a hydraulic press.
R23 0072
23/71
Screw in new Torx screw (1) and tighten down. Tightening torque, refer to Technical Data 23 11 10AZ.
R23 0069
Output shaft bearings in front case section:
Remove selector arm (1). For this purpose, unscrew screws (4 and 5). Remove bracket (3), spring (2) and selector arm (1). Remove retaining plate (6).
2 4 5
36 23 124
23 1 340
00 5 500
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 5 500
Heat the front case section in the area near the bearing to approximately 80 C (hot air blower). Install bearing, using, if necessary, special tool 23 1 470 and handle 00 5 500 until securely driven into place.
23 1 470
36 23 148
23/72
Outer bearing race of countershaft in front case section:
23 1 280
Insert special tool 23 1 280 into the bearing shell (1).
36 23 126
Apply special tool 33 4 020. Screw on special tool 23 1 300.

33 4 020 23 1 300
Pull out bearing shell.
36 23 127
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
Push in bearing shell (1) insert with special tool 23 1 260 and handle 00 5 500.
00 5 500
Locking device (2).
23 1 260
36 23 147
23/73
Install retaining plate.
4 3
2 1
For this purpose, push locking bolt (2) outward with a screw (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. Tightening torque, refer to Technical Data 23 11 17AZ. Remove screw (1).
36 23 149
Note installation position of the pressure pin. Beveled sides must face each other inwards.
36 23 233
Install roller (1) with selector arm (2).
36 23 150
2 3
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 547 gasket compound. gasket compound, refer to BMW Parts Service.
K
36 23 151
23/74
23 1 250
To ease assembly (strong spring force), insert special tool 23 1 250 in the selector arm and push sleeve (1) up to the case. While in this position, install screw (2) with Loctite 243 screw locking varnish and attach loosely. Then install screw (3) with Loctite 243 screw locking varnish and secure. Tighten screw (2) last.
3
36 23 234
23/80
23 23 508 Detaching and mounting all synchronizing devices S5D 200G/ 250G
Transmission removed. Completely remove and install input and output shafts, refer to 23 21 505.
Remove gears and shafts with selector rods from special tool 23 2 400.
23 2 400
36 23 177
Remove selector rods (1). Separate layshaft from gears and shafts.
1
36 23 130
Remove input shaft, needle bearing (1) and 5th gear synchronizer ring.
36 23 174
23/81
1
To ease assembly, insert the output shaft in special tool 23 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.
2
36 23 205
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.
4 5
2 3
36 23 132
1 2 3
Single taper synchronization: Remove 1st gear wheel (1), needle bearing (2) and synchronizer ring (3) from the output shaft.
36 23 206
Lift out circlip (1). Pull off 1st/2nd gear sliding sleeve (2).
Caution! Loose thrust pieces, balls and springs.
1 2
Installation: Replace circlip (1).
36 23 133
23/82
Separate 2nd gear wheel (2) and guide sleeve (1) from the output shaft by pressing.
2
36 23 134
23 1 490
Remove reverse gear wheel, synchronizer ring and guide sleeve (1) from the output shaft with special tool 23 1 490 by pressing.
1 R
36 23 136
Prior to assembling gears and shafts, check all synchronizing devices for wear. For this purpose, determine gap measurement X between synchronizer ring and the corresponding gears. 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
2 1 3
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
23/83
23 1 290
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 until tight.
1 2
Caution! While pressing on, ensure that the detent lugs (2) catch in the openings in the guide sleeve.
36 23 165
Install appropriate circlip (1). Circlips are available in Parts Service from 2.0 ... 2.3 mm in increments of 0.05 mm. Max. permissible end float X: 0.04 mm.
36 23 166
Insert 3 thrust pieces (1) with bevels outward and springs (2) in guide sleeve openings.
1 2
36 23 207
Attach sliding sleeve (1) with the orientation groove (2) to the reverse gear wheel (3).
2 3
36 23 208
23/84
1
Tilt thrust pieces (1) out of the sliding sleeve separately far enough that balls (3) can be placed on the springs. Push in balls (3) and simultaneously press the thrust pieces into the sliding sleeve. Insert 5th gear synchronizer ring into the sliding sleeve. Pull the sliding sleeve upwards uniformly as far as the lock (neutral position).
36 23 209
Rotate the output shaft so that the drive end faces up. Connect needle bearing (1) and 2nd gear wheel (2) to the output shaft.
Note: Coat needle bearing surfaces with ATF-oil.
2 1
36 23 210
Double taper synchronization:
4 8 3 1 2 5 7 6
36 23 167
Note: On renewal, the 1st/2nd gear synchronization must be completely renewed. Attach taper ring (2), friction ring (3) and synchronizer ring (4) so that the lugs (5) of the friction ring catch in the opening (6) on the 2nd gear wheel (1). Lugs (8) on the synchronizer ring (4) catch in the opening (7).
23 1 290
Heat 1st/2nd gear guide sleeve to approx. 120 C (hot air blower) 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 in the opening in the guide sleeve.
36 23 168
23/85
Single taper synchronization: Position synchronizer ring (1).
36 23 211
23 1 290
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.
3
36 23 212
Insert 3 thrust pieces (1) with bevels outward and 3 (pressure) springs (2) in guide sleeve opening.
1 2
36 23 207
Double taper synchronization: Position sliding sleeve (1).
36 23 213
23/86
5 6 4 3 1
Single taper synchronization: Attach sliding sleeve (1) with the orientation groove (2) to the 2nd gear wheel. Lug (3) on the sliding sleeve point towards the middle of the opening (4), or, as the case may be, the teeth with the grooves (5) towards the opening (6) of the sliding blocks.
2
36 23 214
Tilt thrust pieces (1) out of the sliding sleeve separately far enough that balls (3) can be placed on the springs. Push in balls (3) and simultaneously press the thrust pieces into the sliding sleeve.
36 23 209
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
Install appropriate circlip (1). Circlips are available in Parts Service from 2.0 ... 2.3 mm in increments of 0.05 mm.
Max. permissible end float X: 0.04 mm.
36 23 170
23/87
1
Double taper synchronization: Connect needle bearing (5). Install synchronizer ring (6), friction ring (4) and taper ring. 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 bearing surfaces with ATF-oil.
3 5 6 4 2
36 23 171
4 1 2 3
Single taper synchronization: Connect needle bearing (1). Position synchronizer ring (2) with the lugs (3) to the sliding blocks. Note: Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil. Connect 1st gear wheel (4).
36 23 236
Connect roller bearing (1), 5th gear synchronizer ring (2) and input shaft to the output shaft (3).
3 1 2
Note: Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil. Lift off input and output shafts from special tool 23 2 400 and lay to the side.
36 23 237
Layshaft: 3rd/4th gear synchronizing device: For assembly, insert layshaft in special tool 23 2 400. Lift out circlip (1). Installation: Replace circlip (1).
36 23 137
23/88
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 4 tabs outwards with pliers for this purpose.
Remove supporting ring (2) (two parts) and stop disc (3).
Installation: Replace closing ring (1).
36 23 238
Remove 4th gear wheel (1), synchronizer ring (2) and needle bearing (3).
1 2 3
36 23 140
Pull 3rd/4th gear sliding sleeve upward.
36 23 217
23/89
Fit countershaft in a press. Press off 3rd gear (1), guide sleeve (2) and bearing bush (3) from the countershaft.
2 1
36 23 141
Prior to assembly, check all synchronizing devices for wear. For this purpose, determine gap measurement X between synchronizer ring and the corresponding gears. 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
Connect needle bearing (1), 3rd gear wheel (3) and synchronizer ring (2).
2 3
Note: Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil.
1
36 23 153
23 1 290
Heat guide sleeve to approx. 120 C (hot air blower) and position on the layshaft. Position 3rd/4th gear guide sleeve and press on with special tool 23 1 290 until secure.
Caution! While pressing, ensure that the detent lugs (1) catch in the opening in the guide sleeve.
36 23 155
23/90
Heat inner bearing race (1) to approx. 80 C (hot air blower) and push onto layshaft until limit stop.
36 23 156
Insert 3 thrust pieces (1) with bevels outward and 3 (pressure) springs (2) in guide sleeve opening.
1
36 23 239
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.
2 1 5 3
36 23 240
1 3
Tilt thrust pieces (1) out of the sliding sleeve separately far enough that balls (3) can be placed on the springs. Push in balls (3) and simultaneously press the thrust pieces into the sliding sleeve. Insert 3rd gear synchronizer ring into the sliding sleeve. Pull the sliding sleeve upwards uniformly as far as the lock (neutral position).
36 23 241
23/91
Connect needle bearing (1), synchronizer ring (2) and 4th gear wheel (3) to the layshaft.
2 1
36 23 159
Slip stop disc (1) over the gearing up to the bearing surface.
36 23 160
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 of 0.05 mm are available in Parts Service.
36 23 161
Attach special tool 23 2 410 to the layshaft.

23 2 410
Clip the closing ring (1) with 4 fastening lugs into the groove (3).
1 3
36 23 162
23/92
Heat fixed wheel to approx. 180 C (heating plate). Check with thermometer. Thermometer, refer to BMW Service Workshop Equipment Planning Documentation. Position layshaft in a press. Place fixed wheel on the layshaft and press firmly into place with special tool 23 1 290.
23 1 290
36 23 163
Insert circlip (1).
36 23 137
Connect layshaft together with input and output shafts. Attach 3rd/4th gear switch rod (1), 1st/2nd gear switch rod (2) and 5th/reverse switch rod (3).
3
36 23 176
23/51
23 21 505 Removing and installing/replacing complete input and output shafts (S5D 200G/ E36 M41)
Transmission removed.
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 special tool 23 0 100.
00 1 490
23 0 100
36 23 100
Remove clutch release lever and release lever, refer to 21 51 500

23 1 210
23 0 020
36 23 102
23/52
Pull off output flange.
33 1 150
Note: If ease-of-movement is impaired, remove output flange with special tool 33 1 150.
36 23 103
00 5 010
36 23 218
Remove cap (1).
36 23 104
Remove compression springs (1) and cylinder pins (2).
36 23 105
23/53
3
Remove locking stops and ball stops (3) (5 off) with help of a magnet (4).
36 23 106
Note: Note locking pin (1) in the central selector rod!
36 23 107
Locking pin (1) on middle selector rod (2) must locate in centre of selector rod.
2 1
Note: To secure the position of the locking pin (1), the transmission must be shifted into 2nd gear.
R23 0088
Shift into 2nd gear:
1 2
Insert splint driver or screwdriver (1) in bore of selector shaft (2). Twist selector shaft (2) up to 1st left detent and press into the transmission.
R23 0061
23/54
Unfasten screws.
R23 0062
Remove sealing ring.
R23 0063
Remove screw (1), reverse gear switch (2). Lever out cap (3).
1 3 2
36 23 109
Remove spring (4) and arrester bolt (5).
4
36 23 110
23/55
Unscrew screws (1 and 2).
36 23 219
Drive dowel pin (1) out towards clutch case with a cotter pin extractor.
R23 0064
Drive out cotter pin (2) with a cotter pin extractor.
R23 0065
Unfasten screws on transmission case (9 off).
R23 0066
23/56
23 1 141
Remove transmission from assembly frame 00 1 490 and 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.
23 1 142
Pull off rear case section.
23 1 143
36 23 114
Remove middle selector rod until all 3 selector rods are at the same height.
36 23 196
Remove retaining plate (1) and magnetic disc (2).
2
36 23 117
Withdraw pin (3).
6 5
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).
36 23 118
23/57
Place front case section and gear train on special tool 23 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.
1
36 23 121
23 2 460
Caution! To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft during removal of the circlip (3). Lift out circlip (3) and pull off over special tool 23 2 460.
36 23 197
23/58
Take off spacer (4).
36 23 198
Secure special tool 23 1 141 to front case section with 2 screws. Pull front case section from gears and shafts.
23 1 141
36 23 123
Remove reverse gear (3) with reverse gear pins (2).
3
36 23 128
Remove complete gear train from special tool 23 2 190 with selector rods (1)
1
36 23 130
23/59
Reassemble transmission:
Install complete gear train in special tool 23 2 190 with selector rods.
23 2 190
R23 0089
3 2
Install reverse gear with collar (2) facing upwards, then install 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 reverse gear with Loctite 574 gasket compound. Gasket compound, refer to BMW Parts Service.
1
36 23 222
Check end float of the input shaft.
1
23 2 420
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.
X 2
36 23 173
Note: Spacer discs (2) can be obtained from Parts Service in thicknesses (X) of 2.3 ... 2.65 mm.
23/60
2
Heat input shaft inner bearing race (1) in the front case section to approx. 110 ... 120 C (hot air blower). Heating temperature must be maintained precisely: check with a temperature measuring device.
Thermometer, refer to BMW Service Workshop Equipment Planning Documentation. Align selector rods with one another. After heating, insert the roller bearing (2) with thick grease into the bearing sleeve with large diameter facing upwards.
36 23 223
Carefully attach the front case section.
Note: The 5th gear synchronizer ring can jam. After completely assembling the transmission, the 5th gear synchronizer ring can be loosened again by twisting the output/input shafts against each other.
36 23 224
Install spacer (5).
23 2 460
6 5
Caution! To avoid damaging input shaft, special tool 23 2 460 must 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
23/61
Coat sealing lip of new radial seal with ATF oil.
23 2 460
Push radial seal (1) over special tool 23 2 460 up to case. Remove special tool 23 2 460.
36 23 225

23 2 430
1
36 23 226
Install guide tube. Install screws with Loctite 243 screw locking varnish. Tightening torque, refer to Technical Data 23 11 2AZ.
36 23 120
Secure reverse gear shaft in front case section.
Install screw (1) with Loctite 243 screw locking varnish and tighten. Tightening torque, refer to Technical Data 23 11 6AZ. Loosen screw (2) from special tool 23 2 190.
36 23 182
23/62
Remove front case section and gear train from special tool 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.
2 1
Insert gearshift rail (2) with the opening upward into the case.
36 23 184
Install pivot lever with wider head (1) facing the selector rod (2). Ground side of pivot lever must point towards case. Attach pivot lever with the pin (3).
36 23 227
23/63
Install locking pin (1) in the selector rod (2) with Vaseline and secure in the centre.
36 23 228
23 2 440
Place retaining plate (1) with flat side uppermost on 2nd gear on countershaft. Screw special tool 23 2 440 into the retaining plate (1) Install magnetic disc (2) in the case. Align selector rods with one another. Coat locating face of reverse gear shaft (3) with Loctite 574 gasket compound. Clean case sealing surfaces and coat with Loctite 547 gasket compound. Gasket compound, refer to BMW Parts Service.
1 2
36 23 229
Lift radial seal on selector shaft out of rear case. Heat inner bearing race (1) and rear case section in area around bearing to 110 ... 120 C (hot air blower). The heating temperature must be precisely maintained.
Check with a thermometer.
36 23 230
23/64
Fit rear case firmly home on the gear train.
23 2 440
Install 3 screws with new sealing rings. Remove special tool 23 2 440. Screw in fourth screw with new sealing ring. Tighten down all screws. Tightening torque, refer to Technical Data 23 11 17AZ.
36 23 187
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.
00 1 490
23 0 100
36 23 100
R23 0064
R23 0065
23/65
Screw in all case screws and tighten down. Tightening torque, refer to Technical Data 23 11 1AZ.
R23 0066
Loosen bolt (1). Install screw (2) with Loctite 243 locking varnish. Tighten the screws (1 and 2). Tightening torque, refer to Technical Data 23 11 6AZ.
36 23 219
Install radial seals for selector and output shafts:

24 0 110
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 tool 23 1 240.
23 1 240
36 23 188
23/66
Heat output flange to approx. 80 C (hot air blower) and fit to output shaft.
23 1 210 23 0 020
Coat thread and locating face of collar nut (1) with Loctite 243 locking varnish. Brace output flange with special tool 23 0 020. Tighten collar nut (1) with special tool 23 1 210. Tightening torque, refer to Technical Data 23 21 1AZ.
36 23 189
Install arrester and locking balls. Order: Locking ball (1), arrester ball (2) and locking pin (3).
2 1 3
36 23 202
Install springs (1) and cylinder pins (2).
36 23 105
23/67
Attach cap (1). Install screws with Loctite 243 screw locking varnish and secure.
36 23 231
Install arrester bolt (1) and spring (2).
1 2
Note: Roller (3) must be positioned horizontally.
3
36 23 203
Install shear-off screw (1) with Loctite 243 locking varnish and tighten down. Install the reverse gear switch.
1 3 2
Tightening torque, refer to Technical Data 61 31 3AZ. Knock in plug (3).
36 23 204
23/75
23 21 706 Replacing bearings on all transmission shafts (S5D 200G/ E36 M41)
Transmission removed. Removing input and output shafts, refer to 23 21 505
00 1 490
Bearings on output shaft in rear section of case (rear case):

Secure rear case on assembly frame 00 1 490 using special tool 23 0 100.
23 0 100
36 23 232
Unfasten screws and remove retaining plates (1).
R23 0068
Drive bearings out with special tools 23 1 340 / 00 5 500.

00 5 500 23 1 340
36 23 116
23/76
00 5 500
Heat rear case beside bearings to approx. 80 C (hot air blower). Install new bearing: if necessary, drive in bearing to limit position with special tool 23 2 450/ 00 5 500.
23 2 450
36 23 145
Clean screws and threaded bores.
Fit retaining plates (1). Coat screws with Loctite 243 and screw down. Tightening torque, refer to Technical Data 23 11 17AZ.
R23 0068
Bearings on countershaft:

Unscrew bolt (1).
R23 0069
23 1 250
Press off bearing (2) with special tool 23 1 250 on a hydraulic press.
R23 0070
23/77
00 7 500 23 1 250
Press off inner bearing race (3) with special tool 00 7 500 / 23 1 250 on a hydraulic press.
R23 0071
Note: Taper (2) on outer bearing race must point upwards.
23 1 040
2 1
Press on new bearing (1) with special tool 23 1 040 on a hydraulic press.
R23 0072
Tighten in new screw (1) and tighten down. Tightening torque, refer to Technical Data 23 11 10AZ.
R23 0069
Output shaft bearing in front section of case:

Unfasten screws and remove retaining plates (1).
R23 0073
23/78
Drive out bearing with special tool 23 1 340 / 00 5 500.
23 1 340 00 5 500
36 23 125
Heat the front case section in the area near the bearing to approximately 80 C (hot air blower).
00 5 500
Install new bearing and, if necessary, drive in bearing to limit position with special tool 23 1 450 / 00 5 500.
23 2 450
R23 0074
Clean screws and threaded bores. Fit retaining plates (1).
Coat screws with Loctite 243 screw locking varnish and screw in. Tightening torque, refer to Technical Data 23 11 17AZ.
R23 0073
Outer bearing race of countershaft in front case section:

23 1 280
Install special tool 23 1 280 in the outer bearing race (1).
36 23 126
23/79
Apply special tool 33 4 020. Screw special tool 23 1 300 on to 23 1 280.
33 4 020 23 1 300
Pull out bearing shell.
36 23 127
Install new bearing shell (1) with recess on bearing shell aligned with the locking device (2) in the case.
34 23 213 U
Drive bearing shell (1) into limit position with special tool 23 1 260 / 00 5 500.
00 5 500
23 1 260
36 23 147
23/93
23 23 508 Dismantling and assembling all synchronizer units (S5D 200G/ E36 M41)
Transmission removed. 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.
1
36 23 130
Dismantling input and output shafts:
1 2
Place complete input shaft (1) and output shaft (2) on special tool 23 2 190.
23 2 190
R23 0075
Remove input shaft (1) from the output shaft.
R23 0076
23/94
1 2
Remove roller bearing (1) and synchronizer ring for 5th gear (2).
R23 0077
Lift out circlip (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.
2
36 23 205
Place output shaft (1) with output end upwards on special tool 23 2 190.
23 2 190
R23 0078
Remove gear from 1st gear (1) and needle bearing (2).
Remove synchronizer ring (3), taper ring (4) and friction ring (5).
4 5
2 3
36 23 132
23/95
Note: When removing the sliding sleeve, pressure pieces, balls and springs drop out.
1 2
Remove sliding sleeve for 1st/2nd gear (2).
36 23 133
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.
2
36 23 134
Remove synchronizer ring for 2nd gear (2).
R23 0079
Remove friction ring (3).
R23 0080
23/96
Remove taper ring (4).
R23 0081
Remove gear from 2nd gear (5) and needle bearing (6) from the output shaft.
6
R23 0082
23 1 490
Press guide sleeve (1) on 1st/Reverse gears off output shaft and remove using special tool 23 1 490 and hydraulic press.
1 R
36 23 136
Remove synchronizer ring (2), reverse gear (3) and needle bearing (4) from the output shaft.
3 4
R23 0083
23/97
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 press synchronizer 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
Assemble output shaft:
2 1 3
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
23 1 290
Caution! When press-fitting the guide sleeve, ensure that the detent lugs (2) of the synchronizer ringes engage in the recesses in the guide sleeve.
1 2
Heat guide sleeve for 5th/Reverse gears (1) to approx. 120 C (hot air blower) and fit on output shaft, if necessary pressing firmly home using special tool 23 1 290.
36 23 165
23/98
1
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
Insert a pressure piece (1) with a spring (2) in the recesses of the guide sleeve.
1 2
Note: Tapers on the pressure piece point downwards.
36 23 207
Push sliding sleeve (1) towards reverse gear (3) with designation groove (2) facing gear.
2 3
36 23 208
23/99
Install ball stops (3 off):
Tilt pressure piece (1) out of sliding sleeve until ball stop (3) can be fitted to the compression spring. Press ball stop (3) into pressure piece (1) and, at the same time, push pressure piece (1) into sliding sleeve.
After installing the 3 ball stops, insert synchronizer ring for 5th gear in the guide sleeve. Press synchronizer ring onto the guide sleeve and pull sliding sleeve uniformly upwards as far as stop (neutral position).
36 23 209
Rotate the output shaft so that the drive end faces up.
Note: Coat needle bearing and races with ATF oil.

Place needle bearing (1) and 2nd gear (2) on the output shaft.
2 1
36 23 210
Fit taper ring (4) on the 2nd gear.
R23 0081
23/100
Fit friction ring (3) on the taper ring.
Note: Friction ring (3) must locate positively in the gear.
R23 0080
Place synchronizer ring (2) on the friction ring.
Note: The synchronizer ring (2) must locate positively in the taper ring.
R23 0079
23 1 290
Caution! When press-fitting the guide sleeve, ensure that detent lugs (1) on the synchronizer ring locate in the recess of the guide sleeve.
Heat guide sleeve on 1st/2nd gear to approx. 120 C (hot air blower) and fit on output shaft, pressing firmly down if necessary with special tool 23 1 290.
36 23 168
Fit one pressure piece (1) with a spring (2) in each recess of the guide sleeve.
1 2
Note: Tapers on the pressure piece point outwards.
36 23 207
23/101
1
Fit sliding sleeve (1) with designation groove facing 2nd gear (2).
R23 0084
Tilt pressure piece (1) out of sliding sleeve until the ball stop (3) can be fitted to the compression spring. Press ball stop (3) into the pressure piece (1) and, at the same time, push the pressure piece (1) into the sliding sleeve.
36 23 209
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 (neutral setting).
36 23 235
Install new circlip (1) and measure 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 23 170
23/102
1
Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil. Fit needle bearing (5) onto the output shaft. Install synchronizer ring (6), friction ring (4) and taper ring (3) in the guide sleeve.
3 5 6 4 2
36 23 171
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.
3 1 2
Fit roller bearing (1), 5th gear synchronizer ring (2) and input shaft (3) onto the output shaft. Remove input and output shafts from special tool 23 2 190 and place to one side.
36 23 237
Dismantling countershaft:
Install countershaft (1) in special tool 23 2 190.
1
23 2 190
R23 0085
23/103
36 23 137
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
Remove 4th gear (1), synchronizer ring (2) and needle bearing (3) from the countershaft.
1 2 3
36 23 140
23/104
Note: When removing the sliding sleeve, the pressure pieces, balls and springs drop out.
Pull 3rd/4th gear sliding sleeve upward.
36 23 217
Press 3rd gear (1), guide sleeve (2) and bearing bush (3) off the countershaft.
2 1
36 23 141
Remove needle bearing (4).
R23 0086
Check synchronizer unit for signs of wear. For this purpose, determine gap measurement X between synchronizer ring and the corresponding gears. 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
23/105
Assemble countershaft:
Fit needle bearing (1), 3rd gear (3) and synchronizer ring (2) to the countershaft.
2 3
1
36 23 153
23 1 290
Caution! When press-fitting the guide sleeve, ensure that the detent lugs (1) on the synchronizer ring locate in the guide 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
Heat inner bearing race (1) to approx. 80 C (hot air blower) and push onto layshaft until limit stop.
36 23 156
Place one pressure piece (1) with a spring (2) in each recess in the guide sleeve.
Note: Tapers on the pressure piece point outwards.
1
36 23 239
23/106
4
Fit sliding sleeve (1) with designation groove (2) facing 3rd gear (3).
2 1 5 3
36 23 240
1 3
Tilt pressure piece (1) out of sliding sleeve until the ball stop (3) can just be fitted to the compression spring. Press ball stop (3) into pressure piece (1) and, at the same time, push the pressure piece (1) into the sliding sleeve.
36 23 241
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
Fit needle bearing (1), synchronizer ring (2) and 4th gear (3) to the countershaft.
2 1
36 23 159
23/107
Slip stop disc (1) over the gearing up to the bearing surface.
Note: The Parts No. points upwards.
36 23 160
Install thrust washer (two halves) with the small diameter (1) facing downwards between thrust washer and gear.
Note: 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 of 0.05 mm are available in Parts Service. Split new thrust washer at the nominal breakage point.
36 23 161
Fit special tool 23 2 390 onto the countershaft.
23 2 390
1 3
Fit locking ring (1) onto thrust washer with special tool 23 2 390. The 4 locating lugs must engage in the groove (3) of the locking ring.
R23 0090
23/108
Heat gear to approx. 180 C (heating plate). Check with thermometer. Thermometer, refer to BMW Service Workshop Equipment Planning Documentation. Fit gear to countershaft and press down to limit position using special tool 23 1 290 and a hydraulic press.
23 1 290
36 23 163
Install new circlip (1).
36 23 137
Fit countershaft with input and output shafts. Fit selector rod 3rd/4th gear (1) , selector rod 1st/2nd gear (2) and selector rod 5th/Reverse gear (3) to the gear train.
3
36 23 176
23/110
23 21 805 Replace the bearings of all transmission 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
Lever out radial sealing ring for the output flange.
Installation: Replace radial sealing ring.
34 23 200 U
Drive out the ball bearing for the output shaft toward the inside, using Special Tool 23 1 440.
23 1 440
34 23 201 U
23/111
Layshaft:
Heat case in area of the ball bearing to about 80 C with a hot air blower. Remove ball bearing (1) toward the inside. Clean the rear case section to remove dirt.
34 23 202 U
Heat rear case section in area of the ball bearing uniformly 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 the shouldered end (1) facing in.
34 23 203 U
If necessary, drive in ball bearings to fit tight.
00 5 500 23 1 220
Output shaft, Special Tool 23 1 470, countershaft, Special Tool 23 1 220 in conjunction with Special Tool 00 5 500 (handle)
23 1 470
34 23 204 U
Install retaining plates. Insert and secure screws with screw retaining agent (refer to BMW Parts Service). Tightening torque, refer to Technical Data 23 11 17AZ.
34 23 205 U
23/112
2
23 2 310
In order to replace the inner bearing race (2), the 3rd/4th gear 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
Bearings in Front Case Section: Input Shaft: Unscrew bolts. Remove retaining plates (1).
1
34 23 207 U
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
Heat case in area of the ball bearing to about 80 C with a hot air blower. Install ball bearing (2); if necessray drive it in to fit tight with Special Tool 23 1 470.
34 23 209 U
23/113
Insert retaining plates (1). Insert and secure screws with screw retaining agent (refer to BMW Parts Service). Tightening torque, refer to Technical Data 23 11 17AZ.
34 23 210 U
Layshaft:
23 1 280
Bearing shell (1) for needle bearing. Place Special Tool 23 1 280 in bearing shell (1).
34 23 211 U
Apply Special Tool 33 4 020. Screw on Special Tool 23 1 300. Pull out bearing shell.
23 1 300
33 4 020
34 23 212 U
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
23/114
00 5 500 23 1 260
Drive in bearing shell (1) with Special Tool 23 1 260 in conjunction with Special Tool 00 5 500 (handle).
34 23 214 U
23/115
23 21 502 Remove and install the input and output 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).
00 1 490
23 0 100
34 23 107 U
Loosen the screws and pull off the guide pipe.
34 23 104 U
Locate and puncture bores (1 and 2) with a marking tool.
Drive in radial sealing ring on one end as far as it will go. 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
23/116
23 2 380
Caution! Special Tool 23 2 380 must be used on the input shaft to remove circlip (3) so that the input shaft is not damaged.
Lift out circlip (3) and pull off over Special Tool 23 2 380. Take off spacer (4).
3
34 23 224 U
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 shaft bolt in the front case section.
34 23 111 U
23/117
1 2
Remove sealing cap (2).
34 23 112 U
Lift out spring (3) and catch pin (4).
4 3
34 23 113 U
Unscrew case bolts.
34 23 114 U
Pull off front case section using Special Tools 23 2 280 and 33 1 301.
33 1 301
Installation: Bearings or elements of the bearing brackets could be damaged while pulling off the front case section.
Always replace bearings or elements after removal.
23 2 280
34 23 115 U
23/118
Remove loose spring (1) and thrust pin (2).
3
R 23 0035
Pull out selector shaft (4).
Caution! Needles on selector shaft.
Take off 5th/reverse gear shift arm upwards.
34 23 117 U
Remove 2 right bearing pins.
34 23 118 U
Remove 3 left bearing pins.
34 23 119 U
23/119
Remove complete locking lever (1). Remove spring (2) and thrust pin (3).
Remove screw (4). Remove reverse gear with needle bearings, thrust washer and half-shell.
34 23 121 U
Puncture through middle of sealing cap (5). Lever out sealing cap (5) with a screwdriver inserted into the hole.
Installation: Replace sealing cap.
34 23 122 U
Engage a gear by hand. Block output flange using Special Tool 23 0 020.
23 0 020
Unscrew bolt (6).
Caution! Left-hand threads.

Take off washer (7). Take out engaged gear.
R 23 0036
23/120
Block output flange using Special Tool 23 0 020.
23 2 320
Unscrew collar nut (1) with Special Tool 23 2 320.
23 0 020
34 23 124 U
Pull out output flange using Special Tool 33 1 150.
33 1 150
34 23 125 U
23 2 250
Compress gear set at 5th/reverse gear operating sleeve with layshaft. Use Special Tool 23 2 250.
34 23 126 U
23/121
23 2 370
Apply Special Tool 23 2 370 on output shaft and layshaft. Apply Special Tool 23 1 050 on case sealing surface and middle of Special Tool 23 2 370.
Caution! Use a piece of wood, plastic or similar on the sealing surfaces.

Press out gear set and layshaft uniformly.
23 1 050
Make sure that the gear set and layshaft do not jam while pressing out.
34 23 222 U
Installation: The bearings or elements of the bearing brackets could

be damaged while pressing out the input shaft and output shaft. Always replace bearings or elements after removal.
Remove the gear set with shift arms for 1st/2nd and 3rd/ 4th gear and layshaft.
34 23 128 U
Installation:
Clean the case. Drive sealing covers (1 and 2) on rear section of housing outwards from inside using a drift.
Installation: Replace sealing caps.
34 23 129 U
23/122
1
Replace the bearings of the output shaft, layshaft and retaining plates (1. . .2), refer to 23 21 805
2 3 4
34 23 199 U
Lever out radial sealing rings (3 and 4) for the output shaft and shift shaft.
34 23 130 U
23 2 250
Compress gear set at 5th/reverse gear operating sleeve with layshaft. Use Special Tool 23 2 250. Place the shift arm for 3rd/4th gear with sliding blocks on the operating sleeve at 3rd/4th gear. Position the shift arm on the 3rd gear wheel of the output shaft. Install shift arm with lock (1) in direction of the left-hand side input shaft.
34 23 131 U
23/123
Place gear set with shift arm in the rear case section.
Place the shift arm for 1st/2nd gear and sliding blocks in the operating sleeve 1st/2nd gear.
Caution! Install shift arm with lock (1) in direction of the left-hand side input shaft.
34 23 132 U
23 2 330
Apply Special Tool 23 2 330 on the output shaft journal. Pull output shaft in to fit tight with Special Tool 23 2 330. Make sure that shift arms and layshaft are not jammed while pulling in; align if necessary. Remove Special Tool 23 2 330.
34 23 133 U
By hand, align the shift arm for 3rd/4th gear with the bore on the case. In this position, turn the bearing pins (2) one after another on the left and right, then secure. Tightening torque, refer to Technical Data 23 31 1AZ.
34 23 134 U
Lubricate sealing lip of radial sealing ring with oil.
23 2 300
Drive in radial sealing ring (3) for the output flange with Special Tool 23 2 300.
Caution! Use a plastic hammer to knock in.
34 23 135 U
23/124
Heat output flange to about 80 C with a hot air blower. Slide output flange on to the output shaft. If necessary, drive on to fit tight with Special Tool 23 1 160.
34 23 136 U
23 2 320
Install collar nut (1) with bolt cement (refer to BMW Parts) that its flat side faces the outplut flange. Block output flange using Special Tool 23 0 020. Secure collar nut with drive socket 23 2 320. Tightening torque, refer to Technical Data 23 21 1AZ.
23 0 020
34 23 124 U
Heat ball bearing inner race (2) for layshaft to about 80 C with a hot air blower.
23 1 160
Press on ball bearing inner race (2) to fit tight with Special Tool 23 1 160; drive on with light knocks if necessary.
34 23 137 U
23/125
Install washer (3) and bolt (4) with bolt cement, refer to BMW Parts.
Caution! Bolt (4) has left-hand threads.
4
34 23 138 U
Remove Special Tool 23 2 250 from the gear set. Engage a gear. Block output flange using Special Tool 23 0 020. Tighten the screw (4). Tightening torque, refer to Technical Data 23 11 10AZ. Disengage the gear.
Insert and drive in sealing cap (1) flush with Special Tool 23 2 150.
23 2 150
34 23 140 U
23/126
Coat half-shell (2) in area of the bolt bore with sealing compound (refer to BMW Parts) and install. Install shaft (3), thrust washer (4), needle bearing (5) and reverse gear (6) with shoulder (7) facing the case.
7 6
3 2 8
Coat shoulder of the bolt head with sealing compound, refer to BMW Parts. Install bolt (8) with bolt cement (refer to BMW Parts), but do not tighten.
4
34 23 141 U
Install 5th/reverse gear shift arm and slide with catch (1) facing to the left in the 5th/reverse gear operating sleeve.
34 23 142 U
Guide in locking lever (1) with long tongue (2) in the slot of the 5th/reverse gear shift arm.
34 23 143 U
23/127
Swing the locking lever (1) inwards and, at the same time, couple it into the recesses of the shift arms 1st/ 2nd and 3rd/4th gear.
1
34 23 144 U
Center locking lever (1) with the bores by hand. Fit and secure the bearing pins (2) and (3) on the left and right. Tightening torque. refer to Technical Data 23 31 1AZ. Check movement of the locking lever.
2
34 23 145 U
Guide in selector shaft (4) horizontally.
Attach 4 rollers with grease.
34 23 146 U
1
23 2 260
Drive in radial sealing ring (1) for the shift shaft with Special Tool 23 2 260.
34 23 147 U
23/128
23 2 270
Hold the shift shaft in neutral position with Special Tool 23 2 270. Use a 8 mm bolt and cylindrical pin (2) from the shift joint or a suitable mandrel for holding the shift shaft.
34 23 148 U
Clean the front case section.
Drive out sealing cap (3) for the catch pin from inside to outside using a punch.
Installation: Replace sealing caps.
34 23 149 U
Replace the bearings of the input shaft and replace the retaining elements (1), refer to 23 21 805 Remove the retaining plates (1).
1
34 23 207 U
23/129
Place magnet (4) in the rear case section. Install needle bearing (5) with the small diameter end on the outside.
Note: Coat needles with grease and press them in to avoid canting of the needles when mounting the front case section.
Clean and coat case sealing surfaces with a sealing compound, refer to BMW Parts.
5 4
34 23 150 U
Hold the 5th/reverse gear shift arm in horizontal position with a piece of string to make installation easier.
34 23 151 U
Mount the front case section as far as centering pins (1). To center the case, screw 2 M8 x 75 mm auxiliary screws opposite one another on the left and right into the rear section of the case.
BMW
34 23 152 U
23/130
Place Special Tool 23 2 293 (thrust ring) from Special Tool 23 2 290 in the front case section.
23 2 293
34 23 153 U
Apply Special Tool 23 2 290 on the input shaft.
1
23 2 290
Place supporting shells (1) on the input shaft that the tapered sides face in. Unscrewing the spindle presses the front case section on to the input shaft.
34 23 154 U
Press the front case section on only so far that the piece of string can still be removed after installation of the right bearing shaft.
2 1
Centre 5th/reverse gear shift arm (1) with the bore and screw in the right bearing shaft (2) by hand, but do not tighten. Remove piece of string. Press front section of housing firmly home.
34 23 156 U
23/131
Remove complete Special Tool 23 2 290.
23 2 270
Remove centering bolts from case. Secure the front section of the case to the rear section. Tightening torque, refer to Technical Data 23 11 1AZ. Remove Special Tool 23 2 270 from shift shaft.
34 23 157 U
Centre 5th/reverse gear shift arm (1) with the bore and screw in the left bearing shaft (2) by hand.
Secure the bearing pins (2) on the lft and right. Tightening torque, refer to Technical Data 23 31 1AZ.
34 23 158 U
Install bearing shaft (3) for the locking lever. This requires turning the transmission until bore (4) in the locking lever is aligned with the bore in the case.
In this position, turn the bearing pins (3) by hand and secure. Tightening torque, refer to Technical Data 23 31 1AZ.
4
34 23 159 U
Coat shoulder of the bolt head with a sealing compound, refer to BMW Parts. Insert the screw (1) for the reverse gear bolt with screw retaining agent, refer to BMW Parts Service. Tighten both screws. Tightening torque, refer to Technical Data 23 11 6AZ.
1
34 23 215 U
23/132
Place catch pins (1 ... 3) with compression springs in the shift arms.
1 2
34 23 216 U
23 2 360
Knock in sealing caps (5 ... 7) with Special Tool 23 2 360.
34 23 217 U
Catch pin (8) and spring (9)
Caution! Check installed position of catch pin (8).

Roller must be horizontal.
34 23 218 U
Install sealing cap (1) in bore (2) with Special Tool 23 2 350 and push in as far as possible.
23 2 350
2
34 23 219 U
23/133
Install circlip (3) and press in as far as groove with Special Tool 23 2 350. Check for correct seating of the circlip (visual inspection). Install the reverse gear switch.
3
34 23 220 U
Install spacer (4).
23 2 380
Caution! Special Tool 23 2 380 must be used on the input shaft while installing circlip (3) to avoid damaging the input shaft.
Slide circlip (3) over Special Tool 23 2 380 and install it in the groove. The circlip must seat in the groove without play. Replace circlip with a circlip of correct thickness. Circlips are available in different thicknesses
3
34 23 224 U
in steps from 2.2 to 2.6 mm. Lubricate sealing lip of radial sealing ring with ATF.
Apply Special Tool 23 2 380 on the input shaft. Push on radial sealing ring (1) as far as case.
23 2 380
34 23 223 U
Remove Special Tool 23 2 380. Drive radial sealing ring (1) in flush using Special Tool 23 2 340.
Caution! Use a plastic hammer to knock in.
23 2 340
34 23 221 U
23/134
Install guide tube. Tightening torque, refer to Technical Data 23 11 2AZ.
34 23 104 U
23/135
23 23 507 Dismantle and re-assemble all the synchronizing devices (S5D 260Z/ 310Z)
Remove the entire input and output shaft, refer to 23 21 502
Pull off the shift arms for 1st/2nd and 3rd/4th gear.
23 2 250
Remove Special Tool 23 2 250.
34 23 160 U
Pull off input shaft (1), synchromesh ring (2) and needle bearing (3).
1 3 2
34 23 162 U
Clamp gear set in a vise fitted with soft jaws on the output shaft. Pull off 5th/reverse gear operating sleeve.
Remove circlip (4) and spacer (5).
34 23 161 U
23/136
Shift the operating sleeve for 1st/2nd gear towards 2nd gear. Place contact surfaces of open tool on the 1st gear wheel. Pull off the guide sleeve, reverse gear wheel with synchromesh ring, pin bearing and bearing bush, 1st gear wheel and thrust washer from the output shaft.
34 23 163 U
Pull off the needle bearing, synchromesh ring, intermediate ring and outer race.
34 23 164 U
Pull off the operating sleeve for the 1st/2nd gear.

Lift out circlip (1). Take off spacer (2).
34 23 165 U
Place contact surfaces of open tool on the 2nd gear wheel. Pull off the guide sleeve, 2nd gear wheel with synchronizing device and pin bearing from the output shaft.
34 23 166 U
23/137
Assembling Gear Set: Place on the pin bearing and 2nd gear wheel with the recesses facing upwards.
34 23 167 U
Install synchronizing device. Consisting of:
1 4 2
Place the inner race (1), intermediate ring (2) with drives (3) in the recesses of the 1st gear wheel and synchromesh ring (4).
34 23 168 U
Check the synchronizing device for the 2nd gear for wear. Measure distance X between the gear wheel and synchromesh ring. In so doing press down uniformly on the synchromesh ring by hand. Specification: at least 0.9 mm. Actual new part distance: 1.1 ... 1.6 mm.
X
34 23 169 U
When replacing, all three parts must be replaced at one time.
23/138
Heat guide sleeve to about 80 C with a hot air blower.
8 6 5 7
Mount the guide sleeve with the long shoulder facing the 2nd gear wheel. When mounting make sure that lugs (5) of the inner race are aligned with recesses (6) in the gear wheel. In addition lugs (7) on the synchromesh ring must engage in grooves (8) of the guide sleeve.
34 23 170 U
Press on guide sleeve to fit tight with Special Tool 23 1 290.
23 1 290
34 23 171 U
Install spacer (2).
1 2
Insert circlip (1). The circlip must seat in the groove without play; if necessary replace spacer (1). Spacers are available in different thicknesses in steps from 1.8 to 2.05 mm.
34 23 172 U
23/139
Install 3 pressure pieces (1) and 3 pressure springs (2) in the recess of the guide sleeve.
1 2
1 2
34 23 173 U
Place the operating sleeve for the 1st/2nd gear with the flat side facing upwards or the slanted side facing the 2nd gear wheel. The three set-back or opened teeth must point to the springs.
34 23 174 U
Tilt thrust pieces (1) out of the operating sleeve separately far enough that balls (3) can be placed on the springs. Push in balls (3) and simultaneously press the thrust pieces into the operating sleeve.
Pull the operating sleeve upwards uniformly as far as the lock (neutral position).
34 23 175 U
23/140
Check the synchronizing device for the 1st gear for wear. Measure distance X between the gear wheel and synchromesh ring. In so doing, press down evenly on the synchromesh ring by hand. Specification: at least 0.9 mm Actual new part distance: 1.1 ... 1.6 mm.
X
34 23 169 U
When replacing, all three parts must be replaced at one time.
3 2 1 5
34 23 176 U
Install synchromesh ring (1), intermediate ring (2), and inner race (3) with lugs (4) in openings (5) of the guide sleeve.
Mount needle bearing. Place 1st gear wheel with grooves (6) facing the lugs (7).
7
34 23 177 U
23/141
8
Heat thrust washer (9) and bearing sleeve (8) to about 80 C with a hot air blower and install then on the output shaft, pressing on if necessary.
Use Special Tool 23 1 290 for thrust washer. Use Special Tool 33 1 342 for bearing sleeve.
34 23 178 U
Inspect reverse gear synchronization for wear. Measure distance X between the gear wheel and synchromesh ring. In so doing, press down evenly on the synchromesh ring by hand. Specification: at least 0.5 mm. Actual new part distance: 0.7 ... 1.15 mm.
X
34 23 179 U
Mount the needle bearing and reverse gear wheel.
34 23 180 U
Place the revers gear synchromesh ring on the reverse gear cone. Heat the 5th/reverse gear guide sleeve to about 80 C with a hot air blower and install it on the output shaft with conical end (1) facing up; if necessary press on to fit tight with Special Tool 33 1 342. Make sure that lugs (3) engage in opening (2).
2 3
34 23 181 U
23/142
Install spacer (5) and circlip (4).
Circlip (4) must seat in the groove without play; replace spacer if necessary. Spacers are available in different thicknesses in steps from 3.6 to 4.0 mm. Gently tap the circlip into place.
34 23 182 U
Fit 3 pressure pieces (1) and 3 compression springs (2) in the recess of the guide sleeve.
34 23 183 U
Install the operating sleeve with shouldered end (1) facing the reverse gear wheel. The three set-back or opened teeth must point to the springs.
34 23 184 U
Tilt thrust pieces (1) out of the operating sleeve separately far enough that balls (3) can be placed on the springs. Press balls (3) in and simultaneously push the thrust pieces into the operating sleeve. Insert 5th gear synchromesh ring into the operating sleeve. Pull the operating sleeve upwards evenly as far as the lock (neutral position).
3
34 23 185 U
23/143
Check the synchronizing device for the 5th gear for wear. Measure distance X between the gear wheel and synchromesh ring. In so doing, press down the synchromesh ring evenly by hand. Specification: at least 0.75 mm. Actual new part distance: 0.95 ... 1.35 mm.
X
34 23 179 U
Install synchromesh ring. Fit the pin bearing and input shaft with 5th gear wheel.
34 23 186 U
Layshaft:
1
23 2 310
Replace the synchronizing device for the 3rd/4th gear. Place Special Tool 23 2 310 at the 3rd gear wheel. Separate the inner bearing race (1), thrust washer, 4th gear wheel with pin bearing, synchronizing device and 3rd gear wheel with pin bearing from the layshaft.
34 23 187 U
23/144
Assembling: Check the synchronizing device for the 3rd/4th gear for wear. Measure distance X between the gear wheel and synchromesh ring. In so doing, press down evenly on the synchromesh ring. Specification: at least 0.75 mm.
X
34 23 179 U
Actual new part distance: 0.95 ... 1.35 mm.
Fit the pin bearing and 4th gear wheel.
34 23 188 U
Pull the operating sleeve for the 3rd/4th gear from the guide sleeve.
Caution! Loose balls, springs and thrust pieces.
34 23 189 U
Place the synchromesh ring on the taper for the 3rd gear wheel.
Heat the guide sleeve for the 3rd/4th gear up to approx. 80 C (hot air blower). Install the guide sleeve with long shoulder (1) facing the 3rd gear. When fitting, make sure that the drive lugs (2) are aligned with the openings in the guide sleeve.
1
34 23 190 U
23/145
23 1 290
If necessary, press the guide sleeve on to fit tight with help of Special Tool 23 1 290.
34 23 191 U
Heat bearing inner race (3) to about 80 C with a hot air blower and install it on the layshaft.
If necessary, press it on to fit tight with help of Special Tool 33 1 342.
34 23 192 U
Install 3 pressure pieces (1) and 3 compression springs (2) in the recess of the guide sleeve.
1 2
1 2
34 23 193 U
23/146
Fit the operating sleeve for the 3rd/4th gear with the offset side (3) facing upwards. The three set-back or opened teeth must point to the springs.
34 23 194 U
Tilt thrust pieces (1) out of the operating sleeve separately far enough that balls (3) can be placed on the compression springs. Push in balls (3) and simultaneously press the thrust pieces into the operating sleeve.
34 23 195 U
Insert 4th gear synchromesh ring (4) into the guide sleeve openings. Pull the operating sleeve upwards uniformly as far as the lock (neutral position).
34 23 196 U
Fit the pin bearing and 4th gear wheel.
Caution! Needle bearings are selected by the manufacturers according to certain tolerances and have a green colour code.
Do not mix up with other needle bearings.
34 23 197 U
23/147
1 2
Heat thrust washer (2) and bearing inner race (1) to about 80 C with a hot air blower and install on the layshaft with shoulder (3) facing down. If necessary, press them on to fit tight with help of Special Tool 23 1 160.
34 23 198 U
23 00 ...
1 2 3
, ,, ,,, ,, , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,, , , , , , , , , , , , , ,, , ,
23/148
5 R
Arrangement of Transmission (S5D 260Z/ 310Z)
,, ,,
34 23 100
Gear wheel 1st gear Gear wheel 2nd gear Gear wheel 3rd gear
4 5 R
Gear wheel 4th gear Gear wheel 5th gear Gear wheel, reverse gear
23/149
23 00 ... Arrangement of Case Front and Rear Section (S5D 260Z/ 310Z)
101 102 103 104 105 106 107 108 109 110 111 112 113 114
Front case section Guide tube Radial sealing ring Bolts Dowel pin Plug Plain bearing Plain bearing Shaft Plug Ball bearing Element Bolts Ball bearing
115 116 117 118 119 120 121 122 123 124 125 126 127 128
Plain bearing Sleeves Plate Needle bearing Ball bearing Magnet Rear case section Cap Sleeve Ball sleeve Radial sealing ring Bolts Radial sealing ring Cover
23/150
23 00 ... Arrangement of Gear Set (S5D 260Z/ 310Z)
23/151
201 202 203 204 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 401 402 403 404 405 406 Circlip Spacer Input shaft Synchromesh ring Circlip 5th gear wheel Layshaft Needle bearing 3rd gear wheel Synchromesh ring Thrust piece Ball Spring Guide sleeve Operating sleeve Needle bearing 4th gear wheel Thrust washer Washer Bolt Grooved ball bearing Circlip Spacer Thrust piece Ball Spring 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 501 502 503 504 505 506 Guide sleeve Operating sleeve Synchromesh ring Reverse gear wheel Bearing sleeve Washer 1st gear wheel Needle bearing Circlip Spacer Inner race Intermediate ring Outer race Guide sleeve Operating sleeve 2nd gear wheel Needle bearing Output shaft Output flange Collar nut Needle bearing Reverse gear wheel Thrust washer Reverse gear bolt Half-shell Bolt
23/152
23 00 ... Arrangement of Gearshift Control Parts (S5D 260Z/310Z)
601 602 603 604 605 606 607 608 609 610 611 612 613 614 615
5th/reverse gear shift arm Sliding blocks Bearing shaft 1st/2nd gear shift arm Locking lever Shoulder shaft 3rd/4th gear shift arm Cap Compression spring Catch pin Circlip Cap Compression spring Locking pin Compression spring
616 617 618 619 620 621 623 624 625 626 627 628 629 630
Stop plate Bolt Roller Selector arm Spring Gate plate Bolt Spring Reversing lever Retainer Compression spring Catch pin Rollers Selector shaft

Rep S5D

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rep S5D

Uploaded by

Copyright:

Available Formats

23/2

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

Remove retainer (1).

Remove cross tube. roadster: Remove reinforcement bracket.

Engine M40: Remove end fire wall, refer to 61 61 270.

Tighten spindle (2).

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

M40/ M42/ M50/ M52 engine:

Support transmission with workshop hoist. Unfasten screws.

Remove retainer (1).

Remove cross tube.

Tighten spindle (2).

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

Support transmission with a workshop hoist. Unfasten screws.

Caution! Depressurize hydraulic system. This involves:

Remove bracket (1) for underbody protection.

Brace propeller shaft on center mount and loosen nuts.

Pull cable connector (1) off reverse gear switch.

Pull cable connector (1) off transmission oil temperature sensor.

Installation: Adjust cable, refer to 25 16 ... .

Unfasten screws and remove transverse tube (1).

Installation: Tightening Torque, refer to Technical Data 41 11 1AZ.

Unscrew holder (4).

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

Installation: Tightening Torque, refer to Technical Data 23 71 2AZ

Attach special tool 11 8 022 to left and right control arms.

Drive out cylindrical pin (2).

Transfer exhaust carrier and backup light switch.

Drive out cylindrical pin (2).

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

Brace output flange with special tool 23 0 020.

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

Note: Use plastic hammer to drive in.

If necessary, lift out retaining plate (1).

Installation note: Do not fit retaining plate.

Brace output flange with special tool 23 0 020.

Unfasten collar nut with special tool 23 1 210.

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

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

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

Unfasten screws and remove guide tube.

Installation note: Tightening torque, refer to Technical Data 23 11 2AZ.

Caution! Use a plastic hammer for driving in seal.

Unfasten screws and remove guide tube.

Remove special tool 23 2 460 from the transmission input shaft.

Remove clutch release unit and release lever, refer to 21 51 500

When fitted: Lift out lockplate (1).

Unfasten collar nut with special tool 23 1 210.

Pull off output flange.

Note: If output flange has ease-of-movement with special tool 33 1 150.

Remove radial seal with special tool 00 5 010.

Remove cap (1).

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

Remove sealing ring.

Unscrew screws (1 and 2).

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

Pull off rear case section.

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

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

Unfasten screws and remove guide tube.

Remove closing ring (4).

Lift out spacer disc (5).