1997 BMW 528i drive

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This repair group covers general application information for
the clutch, manual and automatic transmissions, shift linkag-
es and driveshaft.
Drivetrain
I ZF manual transmission I
BMW E39 models are equipped with a longitudinal drivetrain.
The transmission is bolted directly to the rear of the engine.
A
driveshaft connects the output shaft of the transmission to the
rear final drive. Individual drive axles with integrated constant
velocity joints transfer rotational power from the final drive
unit to the rear wheels.
4 Due to different power characteristics and performance re-
quirements, various manual transmissions are used in mod-
els covered by this manual. Manual transmission
applications are given in the table below.
For manual transmission specifications or repair procedures,
refer to
230 Manual Transmission.
Manual transmission models use a single disc clutch with
dual-mass flywheel. For further information, see
210 Clutch.
The manual transmission metal ID plate is mounted on side of
transmission. Do not rely on numbers cast on transmission
case for identification.
Manual transmission applications
Model Year Engine Transmission
5251 2001 - 2002 M52TU, M54 Getrag S5D 250G
528i 1997-2002 M52 ZF S5D 3202

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21 0-8
Clutch
4 Remove hydraulic line locking clip (1) and pull line (2) off
master cylinder.
CAUTION-
. To prevent brake fluidspill, wrap clutch master cylinder with
shop rags when removing hydraulic fluid lines from master
cylinder.
* Brake fluid damages paint andstains carpets. Clean off
any brake fluid on or
in the car immediately.
- Remove master cylinder with supply hose
4 Remove switch module from master cylinder.
Press locking button
(A) to release harness connector.
Pull harness connector
(8) off switch module.
Use screwdriver to lever
off switch module (C).
- Installation is reverse of removal.
CA UTlON-
Switch module must snap firmly into place on the master cyl-
inder during installation.
Tightening torques
Clutch master cylinder to pedal cluster
10 Nm (89 in-lb)
Fluid line
to master cylinder or slave cylinder 17 Nm (13 ft-lb)
- Fill fluid reservoir with clean fluid. Bleed clutch hydraulics as
described earlier.
Clutch slave cylinder, replacing
4 Working inside engine compartment, remove left interiorven-
tilation filter housing:
Release
3 plastic taps (A) on duct. Early models: release
latch.
Rotate duct inward to remove.
Disconnect electrical harness to hood position switch.
Release spring lock (B) on interior ventilation housing and
remove housing.
- Pinch off brake fluid supply hose to clutch master cylinder us-
ing BMW special tool
13 3 01 0 or equivalent hose clamping
tool.

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21 0-1 6
Clutch
4 Press new bearing into place using BMW special tool
11 2 350 or equivalent driver.
Clutch, installing (non-SAC)
CAUTIOG
Avoidcontaminating clutch friction surfaces with oilorgrease.
Do not touch these surfaces.
4 Center clutch disc on flywheel using centering tool
Clutch Clutch pressure disc plate
Dual mass flywheel -
5-speed transmission: Special tool 21 2 130
- Install flywheel lock, BMW special tool 11 2 170.
4 Install pressure plate and clutch disc to flywheel. Install and
tighten bolts hand-tight.
CAUTIOG
Be sure clutch disc is facing the correct way The disc should
be
marked 'kngine side" or "transmission side':
- Tighten each clutch bolt one turn at a time until pressure
plate is fully seated. Torque to specification.
Tightening torques
Clutch to flywheel
. M8 (8.8 grade) 24 Nrn (18
ft-lb)
- M8 (10.9 grade) 34 Nrn (25 ft-lb)
- Remove clutch disc centering tool.

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Self-adjusting clutch (SAC), breaking in
With normal driving, 800 to 1000 gearshifts are required to
break in the clutch.
Break in the SAC gradually, with light to medium loads, to en-
sure correct operation and long life. Fast sports driving ma-
neuvers may destroy a new
clutch.The following break-in
procedure helps to create the correct coefficient of friction.
Drive normally on level grade. Starting speeds on level
grade may be up to 2000 rpm.
Upshift and downshift through all the gears at 3500
- 4000
rpm.
On medium grades (approx. 12% and up), start
off at ap-
prox. 2500 rpm for the first 5 or so times.
Tightening torques
Clutch slave cylinder to transmission case 22 Nm (16 It-lb)
Clutch master cylinder to pedal cluster 10 Nm (89 in-lb)
Bralte fluid line to clutch master or slave cylinder 17 Nm (13 ft-lb)
Transmission to engine
M8 (Torx) 22 Nm (16 fl-lb)
. M1O (Torx) 43 Nm (32 ft-lb)
MI2 (Torx) 72 Nm (53 it-lb)
Flywheel to crankshaft
6 cylinder engine (use new self-loclting bolts) 105 Nm (77 ft-lb)
V-8 engine 105 Nm (77 ft-lb)
Clutch to flywheel
M8 (8.8 grade)
M8 (10.9 grade) 24
Nm
(18 ft-lb)
34 Nm (25 ft-lb)

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230-5
Manual Transmission
Manual transmission applications
Manual transmissions used are based on engine application.
See Table a. Manual transmission applications. For gear
ratio specifications,
seeTable b. Manual transmission gear
ratios.
Table a. Manual transmission applications
Model Year Engine Transmission
5251
Sedan 2001 -2002 M54 Getrag S5D 250G
Sport Wagon 2001-2002
M54 ZF S5D 3202
5281 all 1997-2000 M52, M52 TU ZF S5D 3202
530i Sedan 2001
-2002 M54 ZF
S5D 3202
540i Sedan
1997-2002 M62, M62 TU ZF S6S 420G
NOTE-
Do not rely on casting numbers for transmission code
identification.
Table b. Manual transmission gear ratios
-
Getrag Gear Getrag S5D 250G ZF S5D 3202 S6S 420G 5-speed 5-speed 6-speed
6 th 0.83
Reverse 4.04 3.89 3.75
Final drive 3.15
523: 3.23 2.81
5281 530i: 2.93

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230-6
Manual Transmission
Manual transmissions installed in the 5 Series are normally
filled with a "Lifetime" manual transmission fluid
(BMW MTF
LT-I) and do not require periodic fluid changes. Transmis-
sions filled with MTF LT-I lifetime oil are identified with a yel-
low label near the transmission fill plug labeled "Lifetime Oil
MTF-LT-1".
Transmission fluid level, checking
- Drive vehicle for a few miles to warm transmission.
- Raise and safely support vehicle to access transmission
filler plug.
CAUTION-
Make sure the car is stable and well supporfedat all times.
4 Remove side filler plug (B). Insert finger into hole to check
fluid level. If fluid level is up to bottom of filler hole (finger is
wetted by transmission fluid), level is correct.
NOTE-
* Check and fill transmission with car on level surface.
5-speed transmission shown in illustration. 6-speed trans-
mission is similar.
- Install and torque filler plug.
Tightening torque
Transmission drain or fill
plug
to transmission case SO Nm (37 it-lb)
Transmission fluid, replacing
- Drive vehicle for a few miles to warm transmission.
- Raise and safely support vehicle to access drain plug.
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed
for the purpose.
A floor jack is not adequate support.
Check that the
fill plug is not seizedprior to draining
transmission fluid.

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Manual Transmission Selector shaft seal, replacing
(transmission installed)
- Put transmission into second gear.
- Raise and safely support vehicle.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floorjack is not adequate support
- 6-speed transmission: Remove rear engine splash shield
- Remove exhaust system and heat shields. See 180 Exhaust
System.
- Support transmission with transmission jack.
- Disconnect driveshaft at transmission and tie to side. See
260 Driveshaft.
4 Remove transmission crossmember:
Where applicable, release electrical harnesses from
transmission crossmember.
. Remove transmission mounting bolts (A).
Remove transmission crossmember bolts (B).
Where applicable, remove bolts
(C).
NOTE-
5-speed transmission shown in illustration. 6-speed trans-
mission is similar.
- Tilt down rear of transmission.
CAUTION-
Jilting the engine to lower the transmission can lead to
damaae to various components due to lack of clearance.
-
4 Pry sprlng locking rlng (A) out of groove and press pin
of
sh~fl rod.
Detach
sh~ft rod from selector shafl and tie as~de.
(B) out

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230-9
Manual ~ransmissionl
Carefully pry out selector shaft oil seal with BMW special tool
23
0 210, or with a narrow seal remover or small screwdriver.
Coat new selector shaft seal with transmission fluid. Drive
new seal in flush with housing. Use
BMW special seal instal-
lation tool
23 0 220 or equivalent and a soft-faced (plastic)
hammer.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new
loclc nuts.
Check transmission oil level, topping up as necessary.
Tightening torques Aluminum driveshaft to flex-disc
. MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft CV joint to final drive flange
MI 0 (Torx bolt) 70
Nm (51 ft-lb)
M8 (compression nut) 32
Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
MI0 (8.8 grade) 48 Nm (35 ft-lb)
MI0 (10.9 grade) 60
Nm (44 it-lb)
MI2 (8.8 grade) 81
Nm (60 ft-lb)
MI2 (10.9 grade) lo0 Nm (74 ft-lb)
- MI4 140 Nm (103 ft-lb)
Transmission crossmember
to transmission (ME) 21 Nm (15 ft-lb)
. to chassis (M10) 42 Nm (30 ft-lb)