1999 BMW 540i Speed

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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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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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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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230-1 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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230-12
/ 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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--.
- - Manual Transmission
- V-8 engine: Remove heat shield from left front axle support.
< V-8 engine: Remove engine speed reference sensor from
transmission.
- Where applicable, remove brackets for transmission under-
body protection (adjacent to transmission).
4 Support transmission with transmission jack.
- Where applicable, remove reinforcing cross brace from
below driveshaft at transmission.
- Disconnect harness connector from back-up light switch
on transmission.
- Free harnesses for oxygen sensors and back-up lights
from crossmember and transmission.
Remove transmission crossmember: Remove transmission mount bolts
(A).
Remove transmission crossmember bolts (B)
Where applicable, remove bolts (C).
NOTE-
5-speed transmission shown in illustration. Crossmember
assembly for 6-speed transmission is similar.
Disconnect driveshaft from transmission and hang to one
side. See
260 Driveshaft.
I CAUTION- I
Do not damage constant velocity joint orprotective boot at
rear differential.
- 6-cylinder engine: Remove stabilizer bar links and swivel sta-
bilizer bar
u~wards.