2001 BMW 540i manual transmission

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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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Different automatic transmissions are used, depending on
model and model year
and/orproduction date. All of the auto-
matic transmissions are electrohydraulically controlled with
five forward speeds. Automatic transmission applications are
given in the table below.
Automatic transmission applications Model Year Engine Transmission
526 from 911 999 M52 TU ASS 360R
5251 from 312001 M54 ASS 3252
5301 to 312001 M54 ASS 390R
530i from 312001 M54 ASS 3252
540i
from 111 997 M62 TU ASS 4402
Automatic transmission identification metal ID plate is mount-
ed to body of transmission.
4 GM transmission ID tag (arrow) is on left side of transmission
housing, behind transmission selector cable, just above
transmission pan.
< ZF transmission ID tag (arrow) is on left rear of transmission,
just above transmission pan.

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The lubricant used varies, depending on transmission and
model year. Fluid application information is clearly marked on
a label on transmission.
On manual transmission, either ATF (orange label reads
ATF-Oil) or a special BMW lubricant (yellow label reads MTF-
LT
I) is used. See 230 Manual Transmission.
Automatic transmission is filled with either Dexron
Ill ATF
(black transmission ID plate reads ATF-Oil), or special life-
time oil (green transmission ID plate reads Life-Time Oil). See
240 Automatic Transmission.
CAUTION--
If in doubt as to the type of fluid installed in a particular trans-
mission, consult an authorized
BMW dealer service depari-
ment for the latest in operating fluids.

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210 Clutch
........................... General .21 0.2
........................ Special tools .21 0.2
Clutch Hydraulics ................. .21 0.4
Clutch hydraulic system.
bleeding and flushing
................. .21 0.4
Clutch master cylinder. replacing
........ .21 0.6
Clutch slave cylinder. replacing ......... .21 0.8 Flywheel. removing
and installing
................... (6 cylinder engine) 210-12
Flywheel. removing and installing
(V-8 engine) ....................... 21 0-1 3
Transmission pilot bearing. replacing .... 210-1 5
Clutch. installing (non-SAC components) . 210-1 6
Clutch. installing (new SAC components)
. 21 0-17
Clutch.
install in^ (used SAC components) 210-19
Clutch Mechanical ................. .21 0.9 self-adjusting crutch (SAC). breaking in : . 210-21
..................... Clutch variations .21 0.9
................... Clutch. removing .21 0.1 1
Clutch components. inspecting
........ .21 0.1 1

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1 Clutch
This repair group covers replacement of clutch mechanical
and hydraulic components.
BMW 5 Series models with manual transmission use a single
disc hydraulically actuated clutch.
Twoversions of the clutch
are used:
1997
5281 (6 cylinder) uses traditional clutch components.
All 540i (V-8) and 1998 and later
6 cylinder models use a
self-adjusting clutch (SAC).
NOTE-
See 200 Transmission-General for transmission applica-
tion information.
Special tools
Some special tools and techniques are required for clutch re-
pairs. Be sure to read a procedure through before beginning a
job.
< Flywheel loclting tool (V-8 models)
1 (Tool NO. 11 2 070)
-
4 Flywheel loclting tool (6 cylinder models)
(Tool No. 1 1 2 170)
- < Pilot bearino removal tools
11 11 2350 < pilot bearing instaation
(Tool No. 11 2 350) tool

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Anach pressure brake bleeder to fluid reservoir and pump
bleeder a few times to pressurize hydraulic fluid system.
CAUTION-
* Do not exceed 2 bar (29 psi) pressure at the fluid resenfoil
when bleeding or flushing the hydraulic system.
Brake fluid is poisonous, highly corrosive and danger-
ous to the environment. Wear safety glasses and
rub-
bergloves when working with brake fluid. Do not siphon
brale fluid with your mouth. Immediately clean away
any fluid spilled on painted surfaces and wash with wa-
ter, as brale fluid will remove paint.
Always use new brake fluid from a fresh, unopened
container.
Brake fluid will absorb moisture from the air.
This can lead to corrosion problems in the clutch and
brake hydraulic systems, ;nd will also lower the brake
fluid boiling point. Dispose of brale fluid properly.
- Raise and safely support vehicle.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjackstands designed for
the purpose. A floor
iack is not adequate support.
- If necessary, remove transmission splash shield.
Hydraulic system, bleeding
Worlting underneath transmission, connect a hose from
clutch slave cylinder bleeder valve
(arrow) to a container.
Open bleeder valve and allow bralte fluid to expel until
clean fluid comes out, free of air bubbles.
Close bleeder valve and disconnect pressure bleeding
equipment from fluid reservoir.
Slowly operate clutch pedal about
10 times. Fill reservoir
with clean fluid as necessary.
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21 0-6
1 Clutch
Hydraulic system, bleeding
(using
BMW special tool 21 5 030)
4 Working underneath transmission, remove slave cylinder
mounting nuts (arrow) from clutch housing and remove
cylinder. Leave fluid line attached.
4 Use BMW special tool 21 5 030 to press slave cylinder push-
rod completely into slave cylinder.
Hold slave cylinder so that bleeder valve is at highest point.
Open bleeder valve and allow brake fluid to expel until
clean fluid comes out, free of air bubbles.
* Close bleeder valve and disconnect pressure bleeding
equipment from fluid reservoir.
Slowly unscrew and detach special tool 21
5 030 from
slave cylinder.
CAUTION-
Do not remove tool if hydraulic system is pressurized.
- Reinstall slave cylinder.
Tightening torque Slave cylinder to transmission case
22 Nm (1 6 ft-lb)
- Slowly operate clutch pedal about 10 times. Fill reservoir with
clean fluid as necessary.
Clutch master cylinder, replacing
The clutch master cylinder is mounted to the pedal assembly
directly above the clutch pedal.
Working inside engine compartment, remove left interior
ventilation filter housing:
Release 3 plastic taps
(A) on duct. Earlier models use a
single release latch.
Rotate duct inward to remove
Disconnect electrical harness to hood position switch.
Remove filter housing cover.
Release spring
loclc (B) on interior ventilation housing and
remove housing.

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- Raise and safely support vehicle
WARNING-
Make sure the car is stable and well supporied at all times.
Use a professional automotive /iff orjack stands designed for
the
ournose. A floor jack is not adeouate suooort.
- If necessary, remove transmission splash shield.
- Disconnect fluid line from slave cylinder on lefl side of trans-
mission. Place pan under hose to catch dripping fluid.
4 Working underneath transmission, remove slave cylinder
mounting nuts (arrow) from clutch housing and remove
cylinder.
- Installation is reverse of removal, noting the following:
Check for wear on slave cylinder. Any wear except on tip is
caused by misalignment of clutch components.
Lightly coat
pushrod tip with molybdenum disulfide grease
(MolyltoteIB Longterm or equivalent).
. During installation be sure pushrod tip engages recess in
clutch release lever.
Fill fluid reservoir with clean fluid.
. Bleed clutch hydraulics as described earlier.
Tightening
toraues - -.
Clutch slave cylinder to transmission 22 Nm (16 R-lb)
Fluid line to slave cylinder 17 Nm (13 ft-lb)
The transmission must be removed from the engine to access
the clutch mechanical components. It is recommended that
the clutch disc, pressure plate and release bearing be re-
placed during a clutch overhaul.
Besure tocheck the bottom of the bellhousing foroil. If engine
oil is found, check for a faulty rear crankshaft main oil seal.
See
119 Lubrication for rear main seal replacement.
Clutch variations
Two versions of the clutch are used:
1997 528i (6 cylinder) uses traditional clutch components.
All
540i (V-8) and 1998 and later 6 cylinder models from
use a self-adjusting clutch (SAC).