260 driveshaft BMW 525i 1999 E39 User Guide

Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine
Gearshift ~inkaael
Gearshift lever, removing
(manual transmission)
Use the accompanying illustration as a guide when removing
and installing the gearshift linkage.
- Remove shift knob by pulling knob straight off shift lever.
NOTE-
Pull up on the shift knob with about 90 lbs. of force. Do not
twist
knob or locating key can be damaged.
- Squeeze sides of shift boot to unclip from center console.
Pull boot up and off shift lever.
- Remove sound insulation at base of shift lever.
- Raise vehicle to gain access to underside of vehicle.
- --
WARNING-
Male sure the car is stable and well supported at all tfmes.
Use a professional automotwe hft orjaclc stands designed for
the purpose.
A floorjaclc 1s not adequate support.
- Remove complete exhaust system. See 180 Exhaust
System.
- Remove driveshaft. See 260 Driveshaft.
- Support transmission with transmission jack. Remove
crossmember from rear of transmission.
- Lower rear of transmission to access gearshift linkage.
CA UTIOI\C
Tilting the engine to lower the transmission can lead to
damage to various components due to lack of clearance.
4 Working above transmission, disconnect selector rod:
* Pull off shift rod retaining circlip (A).
Remove washer (6).
Disengage selector rod (C) from gearshift lever.

Downloaded from www.Manualslib.com manuals search engine
Gearshift Linkage
- Connect selector rod to shift lever. Lift transmission, install
crossmember and tighten crossmember bolts.
Install driveshaft and heat shield. See
260 Driveshaft.
Reinstall exhaust system. See 180 Exhaust System.
. Lower vehicle. Install shift boot. Push shift ltnob on lever.
Tightening torque
Driveshaft
CV joint to final drive flange
. MI0 (Tom bolt)
70 Nm (51 ft-lb)
. M8 (compression nut) 32 Nm (24 ft-lb) - Driveshaft clamping sleeve
- MI0 ribbed nuts
80 Nm (59 ft-lb)
MI0 compressed nuts 64 Nm (47 ft-lb)
Flex-disc to driveshaft or transmission flange
MlO (8.8 grade) 48
Nm (35 ft-lb)
. MI0 (10.9 grade) 60
Nm (44 ft-lb)
- MI2 (10.9 grade) 100 Nm (74 ft-ib)
MI4 140 Nm (103 fi-lb)
Transmission crossmember
. to transmission 21 Nm (15 ft-lb)
. to chassis 42 Nm (30 ft-lb)

Downloaded from www.Manualslib.com manuals search engine
................. General ............................ 260-2 Driveshaft. installing 260-10
.................. Special tools ........................ .26 0.2 Flex.disc. replacing 260-1 1
..... Driveshaft description ................. .26 0.3 Center bearing assembly. replacing 260-12
........ Troubleshooting ..................... .26 0.3 Front centering guide. replacing 260-13
Constant velocity
(CV) joint. replacing .... 260-14 Driveshaft Service ................. .26 0.6
Driveshaft. aligning
................... .26 0.7
Driveshaft. removing
................. .26 0.8

Downloaded from www.Manualslib.com manuals search engine
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)

Downloaded from www.Manualslib.com manuals search engine
260-1 0
/ Driveshaft
Driveshaft, installing
- Prepare CV joint for reinstallation:
Extend joint to limit.
Clean off old grease and fill with fresh grease
Install new seal.
- Bend driveshaft slightly at center universal joint to install
CAUTION-
Do not allow CVjoint seal to become displaced.
- Align matchmarlts on driveshaft to matchmarks on final drive
and transmission flanges.
- Fit constant velocity joint to final drive input flange. Alternate-
ly tighten two opposite nuts to draw constant velocity joint
evenly into the final drive input flange. Once seated, tighten
down remaining nuts.
I CAUTION-
I Do not reuse self-locking nuts. These nuts are designed to be /
I used onlv once. 1
- Insert bolts in front of driveshafl to transmission output
flange. Counterhold each bolt while tightening nut.
CAUTION-
. Do not reuse self-locking nuts. These nuts are designed to
be used only once.
Avoid stressing the flex-disc when torquing the bolts.
Do this by counterholding the bolts and turning the nuts
on the flange side.
- Position center support bearing and install mounting nuts.
Use new self-locking nuts.
- Install heat shields.
- Install rear transmission support crossmember.
- Install exhaust system. See 180 Exhaust System.
Reconnect oxygen sensor wiring harnesses and reattach
wiring harness retainers to rear transmission support
crossrnernber.

Downloaded from www.Manualslib.com manuals search engine
260-1 2
1 Driveshaft
Install new flex-disc using new self-locking nuts. Molded ar-
rows (arrows) on coupling should point towards flange arms.
4 On vehicles with aluminum driveshaft, use coated washers to
prevent contact corrosion.
- Counterhold bolts while tightening nuts.
Tightening torque
Aluminum driveshaft to flex-disc
M12 (use coated washers) 90
Nm (66 ft-lb)
Steel driveshaft to flex-disc
MI0 (8.8 grade) 48
Nm (35 ft-lb)
- MI0 (10.9 grade) 60 Nm (44 ft-lb)
Coated washers - MI2 (8.8 grade) 5027500 . Mi2 (10.9 grade)
M14 81
Nm (60 ft-lb) 100 Nm (74 ft-lb)
140 Nm (103 ft-lb)
- Install driveshaft as described earlier
Center bearing assembly, replacing
The center bearing assembly consists of a grooved ball bear-
ing in a rubber mount. The bearing assembly is pressed
the driveshaft.
- Remove driveshaft. See Driveshaft, removing
- Matchmark front and rear driveshaft sections before
separating.
Remove bolt (arrow) securing front and rear halves of
driveshaft and pull driveshaft apart.
- Remove shim and dust shield, where fitted
- Use puller to remove center bearing assembly from
driveshaft. onto

Downloaded from www.Manualslib.com manuals search engine
260-14
Driveshaft
Constant velocity (CV) joint, replacing
The CV joint at the rear of the driveshaft is available from
BMW as a separate part.
- Remove complete driveshaft as described earlier in this
section.
< Clean grease off CV joint. Remove retaining circlip (arrow)
from CV joint end of driveshaft.
- Drive out bolts from CV joint.
4 Remove CV joint from driveshaft:
Pry back protective boot
(A).
- Using BMW special tool 26 1 110 on inner race (B), press
or pull joint off shaft.
- Check protective boot for damage. Replace if necessary.
- lnstall new CV joint:
. Working from both sides of joint, inject approximately 80
grams of
OptimolB grease (or equivalent) into joint.
Install new sealing gasket on joint face that mates with pro-
tective boot. Seal fits in groove on outer race of joint.
Clean grease off driveshaft and mating splines on joint.
Apply
LoctiteO 648 to driveshaft splines.
Press new CV joint onto shaft as far as it will go.
CAUTIOI\C
Only press on inner CVjoint race.
- Install new retaining circlip to end of driveshaft,
- Insert CV joint mounting bolts. Be sure to reuse washers.
- Install driveshaft as described earlier in this section.

Downloaded from www.Manualslib.com manuals search engine
330-1 1
Rear Suspension
Coil spring, removing and installing
Raise car and remove rear wheels.
WARNING-
Make sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Remove brake caliper and brake disc. Hang brake caliper
aside with stiff wire. Do not disconnect
bralte fluid hose. See
340 Brakes.
- Remove exhaust system. See 180 Exhaust System.
- Disconnect driveshafl from final drive. See 260 Driveshaft.
- Detach parking bralte cables from mounting bracltets on sub-
frame.
< Support final drive unit from below using transmission jack
and
BMW special tool 33 4 390 or equivalent.
Remove rear suspension
subframe mounting bolts (arrows).
Lower rear
subframe until coil springs can be removed.
When reinstalling springs, replace upper and lower spring
pads if necessary.
Slowly lift suspension
back into position, making sure coil
springs are correctly seated in upper and lower spring seats.
Install and tighten
subframe mounting bolts. Note that on
each bolt, rubber-coated detent plate (arrow) must be in-
stalled at rear in driving direction
- Remainder of installation is reverse of removal
Tightening torques Road wheel
to hub 12OilO Nm (89i-7 ft-lb)
Subframe to body 163 Nm (120 ft-lb)

Downloaded from www.Manualslib.com manuals search engine
330-26
/ Rear Suspension
Remove inner control arm eccentric nut and bolt (A)
Remove control arm ball joint nut (6). Press ball joint out
of wheel bearing carrier.
Lifl out control arm.
Installation is reverse of removal, noting the following:
Use previously made
marks to install eccentric bolt and
nut.
Always use new self-locking nuts.
Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
0 Have car professionally aligned when job is complete.
Tightening
torques
Road wheel to hub 120klONm
(89 i7 ft-lb)
Upper front control arm (traction strut) to 60
Nm (44
ft-lb)
subframe (rear toe adjusting bolt)
Upper front control arm (traction strut) to wheel
65 Nm (48 ft-lb)
carrier
Rear axle assembly, removing and
installing (sedan models)
In case of damage to the subframe, or if a pressed-in bushing
is worn, remove
subframe by removing complete axle assem-
bly.
- Raise car and remove rear wheels.
WARNING-
Make sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place
jack stands under
suspension parts.
- Remove exhaust system. See 180 Exhaust System
- Detach driveshaft from differential. See 260 Driveshaft.
- Remove brake caliper and brake disc. Hang brake caliper
aside with stiff wire. Do not disconnect brake fluid hose. See
340 Brakes.
- Remove lefl and right ABS sensors from wheel bearing car-
riers.
- Disconnect parking brake cable from brake shoe expander.
See 340 Brakes.
- Remove heat shield from above driveshaft.