BMW Manual Transmission Service: GS6-37BZ & S5D 280Z/S5D 320Z (2001-2005)

Application

This document details the servicing procedures for BMW manual transmissions, specifically the GS6-37BZ and S5D 280Z/S5D 320Z models, including 4WD variants, for the 2001-2005 model years.

Manual Transmission Application

Lubrication

Service Intervals

Inspect fluid level when the vehicle is serviced. The transmission is filled with lifetime fluid and should not be drained.

Checking Fluid Level

Note: Numbers in text refer to numbers in figures.

Check lubricant at the fill hole (indicated by '2' in diagrams). Lubricant should be at the bottom of the filler plug hole. To install the filler plug, tighten it to the specified torque. Refer to the "TORQUE SPECIFICATIONS" section for details.

Diagrams illustrating the location of the oil drain plug and filler plug are provided (Fig. 1, Fig. 2). Courtesy of BMW OF NORTH AMERICA, INC.

Recommended Fluid

For model years 1998-2003, manual transmissions were filled with Esso/Exxon MTF-LT-1 lifetime fluid, often identified by a yellow label with "MTF-LT-1" near the filler plug. For these models, no oil change is typically required during the service life of the transmission, unless specified otherwise under "SERVICE INTERVALS".

From model year 2004 onwards, some manual transmissions use Castrol MTF-LT-2 lifetime fluid. This fluid shares the same properties as MTF-LT-1. MTF-LT-1 fluid can be mixed with or substituted for MTF-LT-2 fluid.

Fluid Capacities

The fluid capacity is approximately 1.4 quarts (1.3 liters). The transmission should be filled until the fluid reaches the bottom of the filler plug hole.

Adjustments

Gearshift Linkage

No external adjustment is necessary for the gearshift linkage.

Removal & Installation

Replacing Radial Seal for Output Flange (S5D 280Z/S5D 320Z, 4WD)

Note: Numbers in text refer to numbers in figures.

CAUTION: After completing work, check the transmission oil level. Use only approved transmission fluid. Failure to comply may result in serious damage to the transmission.

Unflange the propeller shaft from the transmission and tie it to one side. Refer to the procedure for "REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT".

For S5D 280Z transmission in E53 models, support the transmission using Special Tools (00 2 030) and (23 0 130). See Fig. 3.

For S5D 320Z transmission in E46/16 models, support the transmission using Special Tools (00 2 030) and (23 0 140). See Fig. 4.

Fig. 3 illustrates the procedure for supporting the transmission and transfer case (E53). Fig. 4 shows supporting the transmission (E46/16). Both courtesy of BMW OF NORTH AMERICA, INC.

Remove the transfer case. Refer to the procedure for "REMOVING AND INSTALLING TRANSFER CASE (MANUAL TRANSMISSION)".

Fit Special Tool (23 0 250) onto the output flange (1). See Fig. 5.

Fig. 5 demonstrates fitting the special tool onto the output flange, courtesy of BMW OF NORTH AMERICA, INC.

Release the collar nut using Special Tool (23 2 320). See Fig. 6.

Fig. 6 illustrates the process of releasing the collar nut, courtesy of BMW OF NORTH AMERICA, INC.

Upon installation, insert the collar nut with Loctite 243. Tighten to the specified torque. Refer to "TORQUE SPECIFICATIONS".

Detach the output flange (1) from the output shaft using a three-claw extractor tool (2). See Fig. 7.

Fig. 7 shows detaching the output flange, courtesy of BMW OF NORTH AMERICA, INC.

Upon installation, heat the output flange (1) to approximately 80°C and push it onto the output shaft.

Remove the radial seal (1) using Special Tool (00 5 010). See Fig. 8.

Fig. 8 details the removal of the radial seal, courtesy of BMW OF NORTH AMERICA, INC.

For installation: coat the sealing lips of the new radial seal (1) with transmission oil. See Fig. 9.

Fig. 9 illustrates the installation of the radial seal, courtesy of BMW OF NORTH AMERICA, INC.

Drive the radial seal (1) in using Special Tool (23 0 190) and a plastic hammer until it is flush.

Replacing Radial Seal for Selector Shaft (GS6-37BZ)

Note: Numbers in text refer to numbers in figures.

CAUTION: After completing work, check the transmission oil level. Use only approved transmission fluid. Failure to comply may result in serious damage to the transmission.

Remove the transfer case. Refer to the procedure for "REMOVING AND INSTALLING TRANSFER CASE (MANUAL TRANSMISSION)".

Shift the transmission into 2nd gear.

Lever the retaining ring (1) out of its groove using a small screwdriver. See Fig. 10.

Fig. 10 shows the process of removing the retaining ring, courtesy of BMW OF NORTH AMERICA, INC.

Slide the locking ring (1) towards the rear and drive out the cylinder pin (2).

Screw in Special Tool (23 0 210) until it is firmly connected with the radial seal (1). See Fig. 11.

Fig. 11 demonstrates pulling out the radial seal for the selector shaft, courtesy of BMW OF NORTH AMERICA, INC.

Pull out the radial seal using Special Tool (23 0 210).

Coat the sealing lips of the radial seal and the selector shaft with gear oil.

Drive in the radial seal using Special Tool (23 0 220). See Fig. 12.

Fig. 12 shows driving in the radial seal for the selector shaft, courtesy of BMW OF NORTH AMERICA, INC.

Torque Specifications

Torque Specifications

⁽¹⁾ Collar nut installed with bolt cement.