Removal of the automatic transmission
These are not detailed step by step procedures are they are
well detailed in the bentley, more like a guideline
1- Place the car on jack stands as high as you can because
you will need to clear the automatic transmission out from
under the car.
2- Remove the 10mm plastic nuts holding the
O2 sensor wire metal shield. Disconnect the O2 sensor and zip
tie it to the exhaust. Remove the exhaust (check your exhaust
hangers and get new ones if need be). Set the exhaust well
away from the work area.
3- Remove the exhaust shield (6 x
13 mm bolts)
4- If you are changing the center bearing,
loosen the 19mm bolt that is attaching both pieces of the
driveshaft with the car in gear and the handbrake on.
Remove all the nuts connecting the driveshaft to the
6- Remove the bolts and nuts connecting the
flex disc to the driveshaft and connecting the flex disc to
the automatic transmission.
Remove the two 13mm bolts holding the center bearing and
remove the driveshaft.
8- Drain the transmission from it's
9- To disconnect the transmision from the engine, you
need to remove 3 bolts connecting the flywheel to the torque
Put the car in gear and remove the plug on the
transmission housing to access the bolts. Rotate the engine
until you can see the bolts.
10- Place a jack under the transmission to
11- Remove the 13mm bolts to remove the
transmission bracket and the transmission mounts. The 525i has
a front and rear bracket...
12- Lower the transmission
using the jack so you can access the transmission
13- Use your super long extention to remove all the
differnent torx bolts holding the transmission, these are the
only thing holding the transmission.
14- Remove that "oups
I forgot" 10 mm bolt holding the transmission shield to the
transmission (passenger side behing the tranny).
Disconnect all electrical connections from the transmission.
Don't forget to remove the gear selector from the
transmission, while you are at it, you might as well remove
the whole shifter selection from inside the car.
disconnect the transmission oil lines from the radiator,
remove all the clamps and disconnect the lines from the
transmission... or cut them if you can't.
17- Ok, the
torque converter is full of transmission oil and the
transmission is really really heavy so be careful when you
remove the transmission.
The transmission should be
strapped to your jack or a proper transmission jack should be
Wiggle the transmission until it comes out, start
lowering the jack while keeping the transmission
18- Place the transmission far away from
the working area, next to the exhaust and the blue bag is
19- Remove the flywheel (impact gun works great)
Enjoy, you are 1/3 of the way to have your car to be 5
speed... Take a break, drink a beer.
Nothing tricky, make sure you have a clutch disc center
tool and a known working or new clutch. The flywheel should be
resurfaced if used.
1- While you are there, use you seal
puller and remove the old crankshaft seal and replace it with
a new one.
2- Install the new bearing in the center
(see picture, bearing installed)
3- Install the new
flywheel and torque it down to the proper value (70ftlb for
the 525i), I use a transmission bolt and one of the flywheel
stud, a wrench between both keeps the engine from turning
while I am torquing the fllywheel.
your centering tool and install the clutch then the pressure
plate and torque the pressure plate down.
And you are done for the clutch. Easy right?
Clutch pedal installation
If you have
a 535i then you are in luck, you do not need to change the
whole pedal assembly because the pedal assembly has the metal
piece welded for the clutch pedal return spring. If in doubt,
change the whole assembly.
1- Make sure the battery is
disconnected. Remove the panels around and under the steering
2- Disconnect all the connectors on the left
side of the steering column, not two are the same so no need
to lable them.
3- If you have airbag, there is a
orange plug near the steering wheel, so remove the lower
steering wheel cover and disconnect it and set it
4- Ok, remove the large nut that is at
the base of the steering shaft all the way down.
5- Now you
need to remove a special stupid "impossible to remove" bolt.
But if you get the #7 sears or snap on bolt removal tool, you
can get it off. The bolt is located mid way down the steering
6- Now this was the hardest part,
remove the last two bolts at the front of the steering colum
and set the steering column aside
7- Remove the old pedal assembly,
pull the clips that retain the throttle bar
and pull it out out of the pedal box. then unclip the brake
pedal and knock the pin out.
8- Install the new pedal
assembly, remove the sensors so you do not break them. The spring for the throttle bar is next.
you need to start the end that goes into the pedal box while
holding the loop end up, once both side are on, put the
bushings into place on the pedal box, then sit in the seat and
push each side home with your feet. Attach the clip over the
What I did with the master cylinder was
to connect it to the metal clutch line prior installing the
pedal assembly, this is really a major pain because you need
to drain the fluid reservoir, pull it out, cut a little bit of
the nipple, insert the master cylinder feed line and then the
5 speed transmission installation
Ok, now the fun part, the 5 speed transmission is pretty
light... well compared to the atomatic transmission.
Clean the transmission up and change all the seals while the
transmission is on the ground, rear seal, shifter selecting
rod seal and front seal.Yes I know that tiny selecting rod
seal is a pain to remove... but do it... I didn't do mine and
then once the transmission was on the car full of oil, it
2- Install a new clutch release bearing lightly
3- NOW IS A GOOD TIME TO INSTALL THE
CLUTCH HYDRAULIC BECAUSE THERE IS LOT OF ROOM UNDER THE
4- Place the transmission on the transmission jack and
wiggle it in place.
5- Bolt it in (good luck with the
starter bolts on 525i)
6- Install the shifter parts
7- Install the shifter arm, the bitch clip, the new yellow
washers and clips. Look into the car to make sure that you
placed the shifter in the correct direction and that you are
happy with the shifter.
8- Install the slave cylinder, replace
with a new one if you are not sure if yours is in good shape.
(Yes I need to change mine)
9- Install the transmission support
brackets with new bushings, connect the reverse light wires
and remove the jack.
Ok, this is done, I do not install the
driveshaft because I want to make sure that everything is
working well, so if you want, you can install the pedal
assembly and then run the car (yes it is loud without exhaust
and yes kind of safe). Go through all the gears to make sure
that all works great.
Now you just have to install the
driveshaft, flex disc, new differential, FLUID in the gearbox
and differential, the exhaust shield, exhaust and you are
Start the car and enjoy shifting
the gears yourself hehehe.