1999 BMW 540i 320

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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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230-7
Manual Transmission
Place drain pan under transmission and remove drain plug
(A) at bottom of transmission.
Drain fluid.
lnstall and torque drain plug.
Remove fill plug
(6) from side of transmission.
Slowly fill transmission with fluid until fluid overflows fill
hole.
lnstall and torque fluid fill
plug.
NOJE-
5-speed transmission shown in illustration. 6-speed trans-
mission is similar.
Fluid capacity
Initial fill
newirebuilt Transmission unit Fluid change
Getrag S5D 250G 1.1 liter (1.2 US qt) 1.0 liter (1 .l US qt)
Getrag S6S 420G 1.9 liter (2.0 US qt) 1.7 liter (1.8 US qt)
ZF S5D 3202 1.3 liter (1.4 US at) 1.2 liter (1.3 US qt)
Tightening torque
Transmission drain or
fill plug to transmission 50
Nm (37 ft-lb)
case
Back-up light switch, replacing
- Raise and safely support vehicle to access back-up light
switch.
WARNING -
4 Unscrew switch from transmission.
Back-up light switch location on transmission varies.
Refer to illustration.
- Install new switch.
Tightening torque Back-up light switch
18 Nm (13 ft-lb)
to transmission
ission fluid level before lowering vehicle.

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230-1 0
I Manual Transmission
Output shaft seal, replacing (5-speed
transmission) (transmission installed)
- Raise and safely support vehicle.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive
lilt orjack stands designed
for the purpose.
A floorjack is not adequate support.
- Remove exhaust system and heat shields. See 180 Exhaust
System
Support transmission with transmission jack.
Disconnect driveshafi at transmission output flange, and
hang driveshaft to side. See
260 Driveshaft.
Remove transmission crossmember:
If applicable, release electrical harnesses from transmis-
sion crossmember.
Remove transmission mounting bolts
(A).
Remove transmission crossmember bolts (6).
Where applicable, remove bolts (C).
- Tilt down rear of transmission.
CAUTIOI\C
Tilting the engine to lower the transmission can lead to
damage to various components due to lack of clearance.
4 Remove collar nut with BMW special tool (see table below) or
suitable thin-walled deep
socltet. Use BMW special tool
23 0 020 or equivalent to counterhold output flange.
Collar nut sockets
Transmission
BMW special tool
Getrag S5D 250G 23 1 21 0 (27 mm)
ZF S5D 3202 23 2 320 (36 mm)
Use puller (BMW special tool 33 1 150 or equivalent) to
remove output flange.
Use BMW special tool
00 5 010 or other suitable seal puller
to remove seal from transmission housing.

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230-1 1
Manual ~ransmissionl
Coat new seal with transmission fluid. Use seal installation
drift (see table below) to drive seal into position until it is flush
with housing.
Output seal drives
Transmission
BMW special tool
Getrag S5D 250G 240110
ZF S5D 3202 23 2 300
inspect sealing surface on output flange. Replace if flange
surface is worn or damaged.
Heat output flange to about 176"
F (80" C) to aid in installa-
tion. This can be done by placing flange in hot water. Rein-
stall output flange to output shaft.
- Coat flange nut with LoctiteB243 and reinstall. Torque in two
stages.
Tightening torques Output flange to output shaft
Stage I 190 Nm (140 ft-lb)
Stage II (after loosening) 120
Nm (89 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new nuts. See
260 Driveshaft.
Check transmission fluid 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
. MI0 (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) I00 Nm (74 It-lb)
M14 140 Nm (103 It-lb)
Transmission crossmember
- to transmission (ME) 21 Nm (15 It-lb)
- to chassis (M10) 42 Nm (30 It-lb)

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230-12
/ Manual Transmission
Output shaft seal, replacing (6-speed
transmission) (transmission installed)
- 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.
- Remove exhaust system and heat shields. See 180 Exhaust
System.
- Support transmission with transmission jack
- Disconnect driveshaft at transmission output flange, and
hang driveshaft to side. See
260 Driveshaft.
Remove transmission crassmember:
If applicable, release electrical harnesses from transmis-
sion crossmember.
Remove transmission and crossmember mounting bolts
(arrows).
5022305201 - Tilt down rear of transmission
CAUTION-
Tlting the engine to lower the transmission can lead to dam-
age to various components due to lack of clearance.
Use screwdriver to pry out output flange collar nut retaining
plate.
Remove collar nut with BMW special tool
23 2 320 or equiv-
alent thin-walled deep socltet
(36 mm). Use BMW special
tool
23 0 020 or equivalent to counterhold output flange.

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Manual Transmission
Input shaft seal, replacing
(transmission removed)
- Remove transmission from vehicle as described later in this
group.
- Remove clutch release bearing end release bearing lever
from inside bellhousing.
4 Remove bolts (arrows) for clutch release-bearing guide
sleeve, noting bolt lengths
(Getrag trensmission shown).
Remove sleeve and any spacers (shims) under it.
Two covered removal holes (arrows) are present in seal.
Thread BMW special tool
23 0 490 or equivalent slide ham-
mer seal puller into one hole and remove seal.
- Getreg S5D 250G transmission:
Place BMW special tool
23 2 460 or similar protective
sleeve over input shaft.
Coat sealing lip of new
seel with trensmission oil and push
over protective sleeve up to transmission housing.
Remove protective sleeve from input shaft.
Use BMW special tool
23 2 430 or similar drifl to drive seal
until fully seated.
- ZF S5D 3202 transmission:
Place BMW special tool
23 2 380 or similar protective
sleeve over input shaft.
Coat sealing lip of new seal with transmission oil and push
over protective sleeve up to transmission housing.
* Remove protective sleeve from input shaft.
Use BMW special tool
23 2 340 or similar drift to drive seal
until fully seated.
- 6-speed transmission:
Fit
cap of BMW special tool 23 2 492 over tool sleeve.
Coat sealing
lip of new seal with transmission oil and push
on tool sleeve. Remove tool cap from tool sleeve.
- Push sleeve with seal on input shaft.
- Use BMW special tool 23 2 491 or similar drift to drive seel
until fully seated.
Remove protective sleeve from input shaft.

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250-8
Gearshift Linkage
-;Ag Gate "",?it.,
Shift interlock, checking function
(automatic transmission)
4 The shift interlock uses a cable between the ignition switch
and the shift lever to lock the shift lever in the park position
when the key is in the off position or removed. This feature
also prevents the key
from being removed from the ignition
lock until the selector lever is in Park.
Shift selector lever to Park position and turn ignition key to
the off position.
Remove ignition key. Checlc that selector lever cannot be
shifted out of Park position.
Turn ignition lkey on and depress
brake pedal. Checlc that
selector lever moves freely from gear to gear.
With selector lever in a gear position other than Park, at-
tempt to turn lkey to off position and remove. Key should not
go into off position.
If any faults are found check cable for lkinks and
check
cable attachment points for damage or faults.
NOTE-
* It must only be possible to remove ignition ley with
selector lever
in Park position.
* Do not link shift interlocl( cable.
Shift interlock repair is covered
in 320 Steering and
Wheel Alignment.

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[~us~ension, Steering and Brakes - General
This section of the manual covers front and rear suspension,
braking and steering systems, and contains wheel, tire and
wheel alignment information and specifications. Also covered
here are the integrated braking and suspension systems in-
cluding
antilock braking (ABS), traction control (ASCIDSC),
and electronic height control (EHC).
Vehicle ride height information is at the end of this repair
group. Alignment information is in
320 Steering and Wheel
Alignment.
Aluminum suspension components
In order to reduce vehicle weight, aluminum suspension com-
ponents are used in some models. A test with a magnet will
easily reveal the metal used. If working with aluminum com-
ponents, be sure to read and follow the cautions below.
CAUTION-
* Due to the chemical and corrosion characteristics of alumi-
num, do not bring into contact with battery acid.
Do not use wire brushes with brass or iron bristles.
Only use brushes with stainless steel bristles.
Do not expose to flying sparks from
grinding/cutting op-
erations.
Do not subject to steel welding splashes.
Do not expose to temperatures over
80°C (176"F),
even for short periods. Temperatures in painting facili-
ties are not a problem.
The E39 front suspension subframe is used as a rigid mount-
ing platform for the front suspension arms, stabilizer bar and
steering gear.
The suspension arms, known as the lower control arms and
the tension struts (thrust arms), are connected to the
sub-
frame through rubber bushings. The arms are connected to
the steering
knucltles in a double pivot configuration.
Each front strut assembly includes a tubular strut and a coil
spring. The upper strut mount includes a bearing. The lower
end of each strut housing is fitted to the steering knuckle. The
integral wheel bearing and hub are bolted to the steering
Iknucltle.
6-cylinder and V-8 models use different steering systems and
other front suspension components.