2000 BMW 528i air con

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Clutch, removing
The procedure given here applies to both non-SAC and SAC
clutch assemblies.
- Remove transmission from engine. See 230 Manual Trans-
mission.
4 Loosen 6 clutch mounting bolts (arrows) evenly
- Remove pressure plate and clutch disc.
WARNING-
The clutch disc contains asbestos. Inhaling or ingesting as-
bestos dust can cause severe health problems. Always wear
an approved respiratorandprotective clothing when handling
components containing asbestos. Do not use compressed
air to clean components. Do not
grind, heat, weld, or sand on
or near anv asbestos materials.
Pull release bearing off transmission input shaft. Remove
clutch release lever by sliding it out of spring clip in direction
of arrow.
Clutch components, inspecting
- Inspect clutch disc for wear, cracks, loose rivets, contamina-
tion or excessive
runout (warping). Replace if necessary.
- Measure clutch disc lining thickness at shallowest rivet head. 7
Clutch and pressure plate wear limits
Minimum clutch disc lining thickness (at rivets)
1.0
mm (0.04 in) - Maxtmum lateral runout
(d~aphragm sprtngs to pressure plate) 0 6 mm (0 02 in)

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230-1 8
Manual Transmission
- Unbolt clutch slave cylinder from side of transmission. Do not
disconnect fluid hose. Suspend slave cylinder from chassis
using stiff wire.
CA UTIOG
Unbolt clutch slave cylinder slowly to prevent air being
drawn into hydraulic system.
. Do not operate clutch pedal with slave cylinder re-
moved from transmission.
4 Put BMW special tool 11 7 370 or appropriate sized spacer
between engine oil sump and front axle support. Lower trans-
mission until engine is supported on spacer.
0 V-8 vehicle: Turn front wheels to prevent strain from being
placed on center tie rod.
All vehicles: Tilting the engine to lower the transmission
can lead to damage to various components due to lack
of clearance at rear of engine. Lower transmission
slowly
- Support front of engine with floor jack.
4 Disconnect shift rod from selector shaft coupling
- Disconnect shift console from top of transmission. See 250
Gearshift Linkage.
6-cylinder: Remove transrnisslon mounting Torx-head bolts
(arrows). Note length and locatlon of bolts.
Remove
transrnlssion by pulling backward untll transmls-
sion Input shaft clears clutch d~sc spl~nes, then pull down-
wards. Lower
transmlsslon jack to remove transrnlsslon. -
- - -
-

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240-2
/ ~utomatic Transmission
This section covers maintenance and replacement of the
automatic transmission for
E39 models.
Automatic transmission internal repairs are not covered.
Such repairs require special service equipment and knowl-
edge. If it is determined that transmission internal
sewice is
required, consult an authorized BMW dealer about a factory
reconditioned unit or a transmission rebuild.
CAUTION-
ATF does not circulate unless the engine is running. When
towing an automatic transmission vehicle, use a flat bed truck
or raise the rear wheels off the ground.
Special tools
Some special tools are required for the removal and installa-
tion of an automatic transmission on the
E39 BMW models.
While these tools are not absolutely necessary, they are es-
pecially helpful when dealing with the removal and replace-
ment of the torque converter.
4 Engine support bracket
(Tool No. BMW
00 0 200.00 0 208)
4 Transmission jack
(Tool No.
BMW 00 2 030)
4 Engine support block (V-8 models) 11 7310 (Tool No. BMW 11 7 310)

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240-6
I Automatic Transmission Automatic transmission fluid (ATF)
The E39 automatic transmission is filled with either Dexron Ill
ATF or Texaco 80728, a life time oil.
CA UTIOI\C
Use only the transmission fluid that is approved for use by
BMW All other fluids will cause non warrantable transmis-
I sion damage.
Mixing different types of transmission fluids will lead to
transmission failure.
NOTE-
The type of transmission lubricant used can be found on a
stickeron the transmission pan. Dexron
111ATF (blacksticker)
reads "ATF-Oil': Special life time oil (green sticker) reads
'Life-Time Oil': If in doubt, consult an authorized
BMW dealer
for alternate fluid use and current information regarding
transmission operating fluids.
ATF level, checking
Check ATF level if there is evidence of a leak, a complaint re-
lated to fluid level or afler transmission repairs.
The automatic transmission is not equipped with a dipstick.
Checking the ATF level requires that the transmission be at
operating temperature during the checking procedure.
NOTE-
Vehicle must be level throughout tests
- Drive vehicle to warm up ATF to operating temperature.
- Connect BMW diagnostic scan tool DiSplus, MoDiC, GTI or
equivalent to determine transmission oil temperature.
ATF level checking
Fluid temperature
30' - 50°C (85' - 120" F)
- With engine running, switch on air conditioning to increase
engine idle speed.
- Apply parking brake.
- While applying foot brake firmly move gear shift selector
lever through
all gear positions, pausing in each gear briefly.

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240-1 3
Automatic ~ransmissionl
- Blow out oil cooler lines with low-pressure compressed air
and flush cooler with clean ATF twice before reattaching lines
to transmission.
CA UTIOG
Wear safety glasses when worling with compressed air:
@ Do not reuse ATF used for flushing.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Reinstall driveshafl using new nuts.
Install new sealing washers on transmission cooling line
banjo bolts.
Install new O-rings on transmission cooler lines, where
applicable.
Inspect engine drive plate (flywheel) for cracks or elongat-
ed holes. Replace
if necessary.
Be sure bellhousing alignment dowel sleeves are located
correctly. Replace damaged sleeves.
Checlc to be sure torque converter is seated correctly in
transmission during final installation.
Use
BMW special tool 24 2 300 to align three mounting
tabs on torque converter with indentations on drive plate
(flywheel).
Fill transmission with clean ATF until oil level is even with
fill hole. Then check fluid level as described earlier.
Adjust gearshift mechanism. See
250 Gearshift Linkage.
NOTE-
In order to avoid difficulties in transmission removal at a fu-
ture time, use washers with Torx-head mounting bolts.

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250-2
I Gearshift Linkage
This repair group covers transmission gearshift and linkage service for both manual and automatic transmission
equipped vehicles.
To gain access to the complete gearshift mechanism it is
necessary to remove the exhaust system and the driveshaft
as described in
180 Exhaust System and 260 Driveshaft.
NOTE-
In models with automatic transmission, the electronic immo-
bilizer
(EWS) prevents starter operation unless the gear po-
sition is Park or Neutral.
Special tools
BMW suggests the use of one special tool in the removal
of the gear shift lever for manual transmission equipped
I I vehicles.
Manual transmission
gearshift linkage
--
4 Gearshift linkage
1. Inner rubber boot
2. Shift lever mounting ring
3. Bushing
4. Shift console
5. Shift lever
6. Selector rod
7. Spacer ring
8. Circlip
9. Dowel pin
10. Locking ring
11. Washer
12. Gear selector rod coupling
13. Locking pin
14. Bushing
4 Sh~fter spanner
(Tool No. BMW
25 1 11 0)
MANUAL TRANSMISSION GEARSHIFT

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260-2
1 Driveshaft
This repair group covers repair and replacement of the
driveshaft and driveshaft components.
Driveshaft repairs consist of replacement of front flex-disc.
center mount or rear
CV joint. If the driveshaft joint is defec-
tive, replace the complete driveshaft.
Drive axle repairs are covered in
331 Final Drive
Special tools
BMW suggests the use of certain special tools in removing,
installing or servicing the driveshaft or its components.
4 Transmission jack
(Tool No. BMW 00 2 030)
4 Transmission support (for use with transmission jack)
/ (Tool NO. BMW 23 0 040)
24 0 170
1
4 Transmission support (for use with transmission jack,
A5S 560Z transmission)
(Tool No. BMW 24
0 170)
24 0 250
I
4 Transmission support (for use with transmission jack,
A5S
4402 transmission)
(Tool No. BMW 24
0 250)
4 Drlveshaft center mount allgnlng yg
Tool No. BMW 26 1 000)

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Driveshaft
4 Driveshaft center slide nut spanner
(Tool No. BMW
26 1 040)
7, 25 1 Ho 4 cv joint removal tool
(Tool No. BMW 26 1 11 0)
support assembly
Driveshaft description
4 The two-piece driveshaft is connected to the transmission by
a rubber flex-disc and to the rear final drive by a constant ve-
locity (CV) joint.
A universal joint is used at the center of the driveshaft and
the shaft is supported in the middle by a center support
bearing. The bearing is mounted in rubber to isolate vibra-
tion.
- The rear constant velocity joint compensates for fore and
aft movement of the drive line.
Troubleshooting
The source of driveline vibrations and noise can be difficultto pin-
point. Engine, transmission, rear axle, or wheel vibrations can be
transmitted through thedriveshaftto the car body. Noises from
thecar may be caused by final drive problems, or by faulty wheel
bearings, drive axles, or even
wom or improperly inflated tires.
NOTE-
For drive axle repair information, see 331 Final Drive
Driveshaft noise or vibration may be caused by worn
ordam-
aged components. Check the universal joint for play. With the
driveshaft installed, pull and twist the driveshaft while watch-
ing the joint. The
BMW specification for play is very small, so
almost any noticeable play could indicate a problem.
Check the torque of the fasteners at the flange connections.
Check the rubber of the flex-disc and center bearing for dete-
rioration or tearing. Check the driveshaft for broken or miss-
ing balance weights. The weights are welded tabs on the
driveshaft tubes. In addition to inspecting for faulty driveshaft
parts, the installed angles of the driveshaft should also be
considered.