2001 BMW 540i lock

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1 Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- lnstall SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques
Clutch to flywheel
- M8 (8.8 grade)
M8 (10.9 grade) 24
Nm (18
ft-ib)
34
Nm (25 ft-lb)
- Slip out clutch centering tool using large bolt.
- Remove flywheel locking tool.
Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CA U TIOG
Do not grease guide sleeve. If guide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- Install transmission. See 230 Manual Transmission
Tightening torques
Transmission to engine
- ME (Torx)
. M1O (Torx)
. M12 (Torx) 22
Nm (16 ft-lb)
43
Nm (32 ft-lb)
72
Nm (53 it-lb)

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230-2
I Manual Transmission
This repair group covers external transmission service, including removal and installation of the transmission unit.
Internal transmission repair is not covered. Special tools and
procedures are required to disassemble and
service the
internal geartrain.
Special tools
BMW specified tools are required for removal and installation
of the manual transmission, as well as the removal and instal-
lation of seals at the transmission input, output, and selector
shafts. If these tools are unavailable, equivalent tools may be
substituted.
4 Transmission jack
(Tool No, BMW 00 2 030)
4 Seal puller
(Tool No. BMW 00
5 01 0)
4 Engine support block (V-8 models)
(Tool No. BMW
11 7 31 0)
4 Engine support bloclc (6 cylinder models)
(Tool No.
BMW 11 7 370)

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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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Manual Transmission
- Thoroughly clean guide sleeve mounting bolts, sealing sur-
faces, and threads. Apply
Loctite8243 or equivalent thread
locking compound to guide sleeve bolts. Reinstall guide
sleeve and
spacer(s).
Tightening torques
Guide sleeve to transmission case
M6 10 Nm (89 in-lb)
* M8 x 22 18 Nm (13 ft-lb)
- Max30 25 Nm (18 ft-lb)
- Reinstall transmission.
TRANSMISSION REMOVAL AND
~NSTALLATION
Removal and installation of the transmission is best accorn-
plished on a lifl using a transmission jack.The engine must be
supported using appropriate support equipment. This allows
the engine to pivot on its mounts to access the upper
Torx-
head bolts at the bellhousing.
WARNING-
Male sure the car is stable and well supported at all times.
Use a professional aulomorive lift or jack slanos des~gned
lor the purpose. A floor jack is nor adequare supporr.
The removal of the transmission may upset the balance
of the vehicle on a
lifl.
Transmission, removing and installing
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 Warnings and Cautions.
V-8 engine: Remove plastic engine cover.
Early models: pry out protective caps (arrows), then re-
move nuts securing cover. Lift off cover.
Later models: depress four studs to release, then
lift off
cover.
- Raise and safely support vehicle
- Remove engine splash shield from underside of vehicle
- Remove exhaust system and heat shields. See 180 Exhaust
System.

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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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240-3
Automatic Transmission
4 Engine support block (&cylinder models)
(Tool No. BMW
11 7 370)
4 Tran5mission support (for use with transmission jack,
A5S 560Z transmission) (Tool No. BMW 24
0 170)
4 Transmission support (for use with transmission jack,
A5S
4402 transmission) (Tool No. BMW 24 0 250)
4 Torque converter socket
(Tool No. BMW 24 1 100)
< Spline bore alignment tool
(Tool No.
BMW 24 2 300)

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Automatic ~ransmissionl
II I
4 Install engine support across engine bay. Raise and safely
support vehicle.
Make sure the car is stable and
we1 supported at all times.
Use a professional automotive lift
orjaclc stands designed for
CAUTIOI\C
Removal of transmission will cause engine to tip unless en-
gine support is used.
- Remove splash shields from underside of vehicle.
- &cylinder models: Detach front stabilizer bar from stabilizer
bar
links. Swivel stabilizer bar upward.
- Drain ATF from transmission as described earlier.
- Remove exhaust system and exhaust heat shield. See 180
Exhaust System.
- Disconnect driveshaft from transmission and hang to one
side. See
260 Driveshaft.
4 With selector lever in park:
Hold
linkage clamping bolt (A) stationary when loosening
selector lever cable clamping nut
(6).
- Loosen cable clamping nut and remove cable from bracket
(ASS
3252 transmission shown).
- Where applicable, disconnect vehicle speed sensor harness
connector.
4 Disconnect main electrical harness connector(s) from trans-
mission by turning bayonet lock
ring(s) (arrows) counter-
clocltwise.
A4S
310R transmission: Harness connector at right rear of
transmission.
ASS
360R / ASS 390R transmission: Harness connector
(arrow) at right rear of transmission.
ASS 3252 transmission: Two connectors (arrows) on left
side of transmission.
ASS 5602 transmission: Harness connector at right rear of
transmission.
- ASS 4402 transmission: Harness connector at top left rear
of transmission.
- Remove wiring harness from transmission housing

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250-1
250 Gearshift Linkage
General ........................... ,250-2 Automatic Transmission Gearshift. .. 250-6
Special tools
........................ ,250-2 Gearshift mechanism, adiustina -
(automatic transmission) ............... 250-6 Manual Transmission Gearshift ..... ,250-3 Automatic shiftlock, checking function Gearshift lever, removing
(automatic transmission) ............... 250-7
(manual transmission) ................ ,250-3 Shift interlock, checking function
Gearshift lever, installing
(automatic transmission)
............... 250-8 (manual transmission) ................ ,250-4