1994 BMW 325i Driveshaft fluid

010-14



FUNDAMENTALS
FOR
THE
DO-ITYOURSELF
OWNER

Fig
.
19
.
Instaf
rear
tow
lug
into
threaded
hole
.

if
absolutely
necessary,
cars
with
automatic
transmissions
can
be
towed
with
the
rear
wheels
on
the
ground,
butthe
tow

should
not
exceed
25
miles
(40
km),at
speeds
at
or
below30
mph
(35
km/h)
.
Be
sure
the
transmission
fluid
hasbeen
topped

off
before
starting
the
tow
.
Always
tow
thecar
with
the
transmis-

sion
lever
in
"N"
(neutral)
.
If
the
tow
must
exceed25
miles
(40

km),
add
one
quart
of
ATF
to
the
transmission,
or
better
yet,
re-

move
the
driveshaft
.
Be
sure
to
drain
or
pump
outthe
added
flu-
id
once
the
tow
has
been
completed
.

NOTE-

"
ATF
draining
and
filling
is
covered
in
240
Automatic
Transmission
.

"
Driveshaft
removal
is
covered
in
260
Driveshaft
.

EMERGENCIES

úo1W¿b

Spare
Parts
Kit

Carrying
a
basic
set
of
spare
parts
can
prevent
a
minor

breakdown
from
turning
into
a
major
annoyance
.
Many
of
the

following
itemswon't
allow
you
todo
major
repair
workon
the

car,
but
they
will
help
in
the
event
of
the
failure
of
something
that

can
disable
thecar
or
compromise
its
safety
.

Spare
Parts
Kit
-
Basic
Contents

"
Drive
belt
(V-belt
or
poly-ribbed)

"
Engine
oil
(one
or
two
quarts)

"
Engine
coolant
(1
gallonof
premixed
50/50
anti-freeze

and
water)

"
Fuse
assortment
(7
.5A,
10A,
15A,
20A)

"
Radiator
hoses
(upper
and
lower)

Spare
Parts
Kit
-
Additional
Contents

"
Exterior
lighting
bulbs
(headlight,
brakelight,
turn
signal,

and
taillight)

"
Wiper
biades

"
Brake
fluid
(new
unopened
bottle,
DOT
4
specification)

"
Main
relay
for
DME
system

020-
1
8



MAINTENANCE
PROGRAM

Fig
.
25
.
Inspect
brake
pads
with
the
caliper
removed
.
Minimum
brake
pad
thickness
shown
by
dimension
(A)
.

NOTE-

The
parking
brake
may
lose
some
of
its
effectiveness
if
it
is
not
used
frequently
.
This
is
due
to
corrosion
build-
up
on
the
parking
brake
drum
.
To
remove
corrosion,
ap-
plythe
parking
brake
just
until
it
begins
togrip,
then
pulí
the
lever
up
one
more
stop
(click)
.
Drive
thecar
approx-
imately
400
meters
(1,300
ft
.)
and
release
the
brake
.
To
recheck
the
adjustment
of
the
parking
brake
see340
Brakes
.

UNDER-CAR
MAINTENANCE

0011920

Manual
transmission
fluid,

checking
and
filling

The
manual
transmission
fluid
leve¡
should
be
checked
at

specified
intervals
.
Check
and
fill
the
transmission
with
the
car

ona
leve¡
surface
.
Transmission
(luid
leve¡
checking
and
re-

placement
procedures
are
covered
in
230
Manual
Transmis-

sion
.

Automatic
Transmission
Service

The
automatic
transmission
is
not
equipped
with
a
dipstíck
.

Therefore,
checking
the
ATF
level
is
an
ínvolved
procedure,

which
includes
measuring
and
maintaining
a
specified
ATF

temperature
during
the
checking
procedure
.

For
more
complete
ATF
service,
including
checking
ATF
lev-

e¡
and
ATF
filter
replacement
procedures,
see
240
Automatic
Transmission
.

Front
suspension
and
steering
linkages,

inspecting

Inspection
of
the
front
suspension'and
steering
includes
a
check
of
all
moving
parts
for
wear
and
excessive
play
.
Also
in-

spect
the
rubber
seals
and
boots
for
cracks
or
tears
that
could

allow
the
entry
of
dirt,
water,
and
other
contaminants
.
See
310

Front
Suspension
.

Exhaust
system,
inspecting



Rear
suspension,
inspecting
Exhaust
system
life
varies
widely
according
to
driving
habits



Final
drive
and
rear
drive
axle
service
consists
of
checking

and
environmental
conditions
.
If
short-distance
driving
pre-



and
changing
the
gear
oil,
inspecting
for
leaks,
and
checking
dominates,
the
moisture
and
condensation
in
the
system
will



the
rear
drive
axle
rubber
boots
for
damage
.
not
fully
dryout
.
This
will
lead
to
early
corrosion
damage
and
more
frequent
replacement
.
The
areas
where
leaks
are
most
likely
to
occur
are
around
the
driveshaft
and
drive
axle
mounting
flanges
.
For
more
infor

Scheduled
maintenance
of
the
exhaust
system
is
limitedlo



mation
on
ídentifying
oil
leaks
and
their
causes,
see330
Rear
inspection
.
Check
for
restrictions
due
to
dents
or
kinks
.
Check



Suspension
.
for
weakness
or
perforation
due
to
rust
.
Check
lo
see
that
all
the
hangers
are
in
place
and
properly
supporting
the
system
and
that
the
system
does
not
strike
the
body
.
Alignment
of
the
sys-



Final
drive
oil
leve¡,
checking

temand
the
location
of
the
hangers
aredescribed
in
180
Ex-
haust
System
.



Check
the
lubricant
leve¡
with
thecar
level
.
Remove
the
oil
filler
plug
.
The
leve¡
is
correct
when
the
fluidjust
reaches
the

edge
of
the
filler
hole
.
Install
and
tighten
the
oil
filler
plug
when
Manual
Transmission
Service



the
oil
level
is
correct
.
See
Fig
.
26
.

Manual
transmissionservice
consists
of
inspectingfor
leaks



The
final
drive
should
be
filled
with
a
special
BMW
lubricant
and
checking
and
changing
the
fluid
.



available
through
an
authorized
BMW
dealer
.
In
addition,
the
lubricant
type
varies
depending
onwhether
or
nota
limited-slip
Evidence
of
transmissionleaks
is
fkely
to
beseenaround
the



differential
is
fitted
.
driveshaft
mounting
flange
and
at
the
bottom
of
the
bellhousing
.
For
more
information
on
identifying
oil
leaks
and
their
causes,
see230ManualTransmissionand210
Clutch
.



Tightening
Torque

"
Finaldrive
filler
plug
to
final
drive
housing
..................
70
Nm
(52
ft-Ib)

Selector
shaft
seal,
replacing

(transmission
instalied)

1
.
Raise
and
safely
support
vehicle
to
access
drain
plug
.

2
.
Support
transmission
with
transmission
jack
.

3
.
Remove
driveshaft
.
See
260
Driveshaft
.

4
.
Remove
transmission
crossmember
and
tilt
down
rear

of
transmission
.

CA
UTION--

Tilting
the
engine
to
lower
the
transmission
can
lead
to
damage
to
various
cgmponents
due
to
lack
of
clearance
.
-On
cars
with
AST
(traction
control)
remove
throt-
tle
body
before
tiltlng
engine
.
-Remove
brake
fluid
reservoir
lf
necessary
.

Locking
pin

á



Locking
clip

8
.
Reinstall
shift
linkage
to
selectorshaft
.

7
.
Coat
new
seal
with
transmission
fluid
.
Drive
new
seal
in

flush
with
housing
.
Use
BMW
special
seal
installation
tool
no
.
23
2
260
orequivalent
and
a
soft-faced
(plastic)

hammer
.
See
Fig
.
4
.

9
.
Fiaise
transmission
and
reinstall
crossmember
.

MANUAL
TRANSMISSION



230-
3

Seal
Selector

_
shaft

5
.
Working
at
rear
of
selector
shaft,
disconnect
shift
link-



Fig
.
3
.



Selector
shaft
oil
sea¡
being
pried
out
with
screwdriver
.

age
from
selectorshaft
.
See
Fig
.
2
.

Fig
.
4
.



Selector
shaftseal
being
installed
.

6542

0012020

Fig
.
2
.



Disconnect
shift
linkage
from
transmission
selector
shaft
by

prying
back
locking
clip
and
pushing
locking
pin
out
.



10
.
Install
driveshaft
using
new
nuts
.
See260
Driveshaft
.

6
.
Carefully
pry
sea¡
out
with
a
narrow
seal
remover
or



11
.
Check
transmission
oil
level,
topping
upas
necessary
.

small
screwdriver
.
See
Fig
.
3
.

Tightening
Torques

"
Driveshaftto
flex
disc/

final
drive
flange
..............
See
260
Driveshaft

"
Transmission
crossmember
to
chassis

M8
........
..
.
...
........
22-24
Nm
(16-17
ft-1b)

M10
........
.
.
...
...
.
.........
42
Nm
(31
ft-Ib)

TRANSMISSIONSERVICE

230-
4



MANUAL
TRANSMISSION

Output
shaft
sea¡,
replacing

(transmission
installed)

1
.
Raise
and
safely
support
vehicle
.
Support
transmission

with
transmission
jack
.

WARNING
-

"
When
raising
thecar
using
a
floor
jack
or
a
hy-
draulic
lift,
carefully
position
the
jack
pad
to
pre-vent
damaging
the
car
body
.
A
suitable
liner
(wood,
rubber,
etc
.)
should
be
placed
between
the
jack
and
the
car
to
prevent
body
damage
.

"
Watch
the
jack
closely
.
Make
sure
it
stays
stable
and
does
not
shift
or
tilt
.
As
the
car
is
raised,
the
car
may
roll
slightly
and
the
jack
may
shift
.

2
.
Remove
driveshaft
.
See
260
Driveshaft
.

3
.
Remove
transmission
crossmember
and
lower
trans-

mission
at
rear
.

CAUTION-

Tilting
the
engine
to
lower
thetransmissíon
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
.
-On
cars
with
AST
(traction
control)
remove
throt-
tle
body
before
tilting
engine
.
-Remove
brake
fluid
reservoir
if
necessary
.

4
.
Bend
back
and
remove
collar
nut
lockplate
.

5
.
Hold
flange
steady
andremove
collar
lock
nut
(use

30mm
thin-walled
deep
socket
.)
See
Fig
.
5
.

Fig
.
5
.



Use
holding
tool
when
loosening
output
shaft
collar
nut
.

6
.
Remove
flange
.
If
necessary,
use
a
puller
.

7
.
Use
a
sea¡
puller
to
remove
seal
from
transmission
housing
.
See
Fig
.
6
.

8
.
Coat
new
sea¡
wíth
transmission
fluid
and
drive
into
po-
sition
until
it
is
flush
with
housing
.
See
Fig
.
7
.

TRANSMISSIONSERVICE

Fig
.
6
.



Puller
used
to
remove
transmission
seal
.

Fig
.
7
.



Output
shaftseal
being
installed
using
seal
driver
(BMW
spe-
cial
tool
no
.
232
300)
.

9
.
Reinstall
output
flange
(and
shims,
if
applicable)
to
out-

put
shaft
.

NOTE-

On
Getrag
S5D200G
and
S5D
250G
transmissions
BMW
recommends
heating
theoutputflange
to
about
176°F
(80°C)
to
aid
in
installation
.
This
canbe
done
by
placing
the
flange
in
hot
water
.

10
.
Coat
bearingsurface
ofcollar
nut
withsealer
and
install
nut
.
Tighten
collar
nut
in
two
stages
.
Insta¡¡
new
lock-
plate
.
Bend
tabs
into
flange
grooves
.

NOTE-

BMW
recommends
the
use
of
a
sealer
such
as
Loctite
®
242
when
installing
the
flange
collar
nut
to
prevent
oil
from
leaking
past
the
threads
.

230-
6



MANUAL
TRANSMISSION

Transmission,
removing
and
installing

1
.
Disconnect
negative
(-)
cable
from
battery
.

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.

2
.
Insta¡¡
enginesupportacrossengine
bay
.
Raise
engine

so
that
weight
of
engine
ís
supported
.
See
Fig
.
10
.

Fig
.
10
.
Engine
support
equipment
used
to
support
engine
from
above
before
removing
transmission
.

3
.
Raise
vehicle
to
gain
access
to
underside
of
car
.

4
.
Support
transmission
with
transmission
jack
.
lf
applica-
ble,
remove
reinforcing
cross
brace
from
belowen-
gine/transmission
.

5
.
Disconnect
harnesscon
nector
from
reverse
light
switch
on
transmission
.

6
.
Remove
completeexhaustsystem
and
heat
shield
.
See
180
Exhaust
System
.

NOTE-

Disconnect
oxygensensor
hamess
connector(s)be-
fore
lowering
exhaust
system
.

7
.
Remove
driveshaft
.
See260
Driveshaft
.

8
.
Disconnect
shift
rod
from
transmission
selectorshaft
.
See
Fig
.
11
.

9
.
Disconnect
shift
console
fromtop
of
transmission
.
See
250
Gearshift
Linkage
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

Washers

Shift



Shift
rod

rod



retaining
clip

0
0
,

Fig
.
11
.
Shift
lever
to
transmission
connection
.

Shift
console

0012024

10
.
Unbolt
clutch
slave
cylinder
from
sideof
transmission
.

Do
not
disconnect
fluid
hose
.
Suspend
slavecylinder

from
chassis
using
stiff
wire
.

CAUTION-

Do
not
operate
clutch
pedal
with
slave
cylinder
re-
moved
from
transmission
.

11
.
Support
transmission
from
below
with
jack
.
Remove
rear

support
crossmember
from
transmission
.
See
Fig
.
12
.

Fig
.
12
.
Rear
transmission
crossmember
(arrow)
.

12
.
Lower
transmission/engine
assembly
until
it
rests
on
front
suspension
crossmember
.

CAUTION-

Tilting
the
engine
to
lower
thetransmission
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
at
rear
of
engine
-On
cars
with
AST
remove
throttle
body
before
tilt-
ing
engine
.
-Remove
brace
fluid
reservoir
if
necessary
.

0013135

13
.
Remove
transmission
mounting
bolts
(Torx-head)
.

Note
length
and
location
of
bolts
.
See
Fig
.
13
.

Fig
.
13
.
Transmission
mounting
bolts
.

0611642

CA
UTION-

Atno
time
should
the
weight
of
thetransmission
be
supported
by
the
transmission
inputshaft
.

NOTE
-

Washers
should
always
be
used
with
Torx-head
bolts
.

Installing
bolts
without
washers
will
make
them
difficult

to
loosen
.

MANUAL
TRANSMISSION



230-
7

Fig
.
14
.
Bellhousing
alignment
dowels
(arrows)
.

16
.
Install
driveshaft
and
preload
center
bearing
bracket
.

Usenew
nuts
when
mounting
driveshaft
to
transmis-

síon/flex
disc
and
final
drive
.
See
260
Driveshaft
.

17
.
Refill
transmission
with
appropriate
lubricant
before

starting
or
towingthe
car
.
See
Transmission
Fluid

Service
earlier
in
this
repair
group
.

14
.
Remove
transmission
by
pulling
backward
until
the
trans-



Tightening
Torques

mission
inputshaft
clears
the
clutch
disc
splines,
then



"
Reinforcing
cross
brace

pulí
downwards
.
Lower
jack
andremove
transmission
.



to
chassis
(M10)
.
...
.............
42
Nm
(31
ft-Ib)

"
Rubber
mount
to
transmission

15
.
Installation
is
reverse
of
removal,
keeping
in
mind
the



or
bracket
nut
(M8)
.
...
.
...
.......
21
Nm
(16
ft-Ib)

following
:



"
Slave
cylinder
to
transmission
......
22
Nm
(16
ft-Ib)

"
When
installing
exchange
transmission,
transfer
parts



"
Transmission
crossmember
to
chassis

from
old
unit
to
exchange
unit



M8
...............
.
.
...
..
22-24
Nm
(16-17
ft-Ib)

"
Thoroughly
clean
inputshaft
and
clutch
disc
splines
.



M10
..............
.
..
..
.......
42
Nm
(31
ft-Ib)

Lightly
lubrícate
transmission
inputshaft
before
in-



"
Transmission
to
engine
(Torx-head)

stalling
.-



M8
..
..................
..
.
..
..
22
Nm
(16
ft-Ib)

"
Be
sure
bellhousing
dowels
are
correctly
located
.
See



M10
.
.................
...
.
..
..
43
Nm
(32
ft-Ib)

Fig
.
14
.



M12
.
..................
..
.
..
..
72
Nm
(53
ft-Ib)

"
Center
rear
of
transmission
in
driveshaft
tunnel
before



"
Transmission
drain/fill
plugs
.
..
.
..
..
50
Nm
(37
ft-Ib)

tightening
transmission
support
bracket
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

240-
4



AUTOMATIC
TRANSMISSION

TRANSMISSION
REMOVALAND

INSTALLATION

Removal
and
installation
of
thetransmission
is
best
accom-

plished
on
a
lift
using
a
transmission
jack
.
Use
caution
and

safe
workshop
practices
when
working
beneath
car
and
low-

ering
transmission
.

WARNING
-

To
lift
the
vehicle
safely,
see010
Fundamentals
for
the
Do-it-Yourself
Owner
.

CAUTION-

"
Be
sure
the
vehicle
is
properly
supported
.
The
removal
of
the
transmission
may
upset
the
bal-
ance
of
the
vehicle
on
a
lift
.

"
Tilting
the
engine
to
remove
the
transmission
can
lead
to
damage
to
various
components
due
to

lack
of
clearance
.
-On
carswith
AST
remove
throttle
body
.
-Remove
brake
fluid
reservoir
if
necessary
.

Torx-head
bolts
are
used
to
mount
thetransmission
to
the

bellhousing
.
Be
sure
to
have
appropriate
tools
on
hand
before

starting
thejob
.

2
.
Install
engine
support
across
engine
bay
.
Raise
and

safely
support
vehicle
.
See
Fig
.
6
.

WARNING
-
"
When
raising
thecar
using
a
floor
jack
or
a
hy-
draulic
lift,
carefully
position
the
jack
pad
to
pre-
vent
damaging
the
car
body
.
A
suitable
liner
(wood,
rubber,
etc
.)
should
be
placed
between
the
jack
and
the
car
to
prevent
body
damage
.

"
Watch
the
jack
closely
.
Make
sure
it
stays
stable
and
does
not
shift
or
tilt
.
As
the
car
is
raised,
the
car
may
roll
slightty
and
the
jack
may
shift
.

CAUTION-

Removal
of
transmission
will
cause
engine
to
tip
unlessengine
support
is
used
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

Fig
.
6
.
Engine
support
equipment
used
to
support
engine
from
above

before
removing
transmission
.

3
.
Raise
vehicle
to
gain
access
to
underside
of
car
.

4
.
Drain
ATF
from
transmission
as
described
earlier
.

5
.
Disconnect
oxygen
sensor
harness
.
Remove
exhaust

system,
and
exhaust
heat
shield
.
See
180
Exhaust

System
.

Transmission,
removing
and
installing



6
.
Remove
driveshaft
.
See
260
Driveshaft
.

1
.
Disconnect
negative
(-)
cable
from
battery
.



7
.
With
selector
lever
in
Park,
disconnect
shift
selector
le-

ver
cable
from
lever
and
remove
cable
bracket
.
Hold

CA
UTION-



linkage
clamping
bolt
stationary
when
loosening

Prior
to
disconnectiog
the
battery,
read
the
battery



clamping
nut
.
See
Fig
.
7
.

disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.

Fig
.
7
.



Selector
lever
cable
clamping
nut
(A)
.
Loosen
cable
clamping
nut
(B)
and
remove
cable
from
bracket
.
Always
counterholdclamping
bolt
when
loosening
nut
.

250-2



GEARSHIFT
LINKAGE

5
.
Remove
driveshaft
.
See260
Driveshaft
.



9
.
Release
gearshift
lever
retaining
ring
from
below
by

turningspecial
tool
90°(
1
/4
turn)
counterclockwise
.
See

6
.
Support
transmission
with
transmission
jack
.
Remove



Fig
.
4
.

crossmember
from
rear
of
transmission
.
See
Fig
.
2
.

Fig
.
2
.



Rear
transmission
crossmember
(arrow)
.

7
.
Lower
rear
of
transmission
to
access
gearshift
linkage
.

CAUTION-

Tilting
the
engine
to
lower
thetransmission
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
.
-On
cars
with
AST
remove
throttle
body
.
-Remove
brake
fluid
reservoir
if
necessary
.

0013135

8
.
Working
below
transmission,
disconnect
shift
rod
from

gearshift
lever
.
Note
washers
on
either
side
of
shift
rod

end
.
See
Fig
.
3
.

v

clip

Shift
rod

Fig
.
3
.



Pull
off
shift
rod
retaining
clip
in
direction
of
arrow
(t)
;
disen-
gage
shift
rod
from
gearshift
lever
(2)
.

MANUAL
TRANSMISSION
GEARSHIFT

BMW
Tool
No
.
25
1
110
orequivalent

Fig
.
4
.



Shift
lever
retaining
ring
being
removed
using
BMW
special

tool
25
1
110
.

10
.
Raise
transmission
and
temporarily
instan
transmission

crossmember
.

11
.
Lower
vehicle
.
Working
from
inside
passengercom-

partment,
pull
upon
gearshift
lever
to
remove
it
togeth-

erwith
retaining
ring
and
rubber
grommet
.

Gearshift
lever,
installing

(manual
transmission)

6532

1
.
Instan
shift
lever,
aligninglocking
tabs
with
openings
in

shift
console
.
Press
down
on
retaining
ring
until
it
clicks
into
place
.
See
Fig
.
5
.

\
Retaining

Fig
.
5
.



Shift
lever
retaining
ring
.
Fit
plastic
tabs
into
slots
of
shift
con-
sole(arrows)
.