260 driveshaft BMW 525i 1999 E39 Workshop Manual

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YOU are now in Volume I
I
Foreword ................... .. ........................................................................\
.......... v
Index
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General, 001 General Warnings and Cautions 002 Vehicle Identification and VIN Decoder
Maintenance OiO 020 Maintenance
Engine
100 Engine-General 110 Engine Removal and Installation
113 Cylinder Head Removal and
Installation
116 Cyiinder Head and Valvetrain 117 Camshaft Timing Chain
119 Lubrication System
200 Transmission-General
2 Transmission 210 clutch 230 ManualTransmission
I20 Ignition System
121 Battery, Starter, Alternator
130 Fuel Injection
160 Fuel Tank and Fuel Pump 170 Radiator and Cooling System
180 Exhaust System
240 Automatic Transmission
250 Gearshift Linkage 260 Driveshaft
Suspension, 300 Suspension, Steering and 330 Rear Suspension
Brakes-General 331 Final Drive
Steering and No Front Suspension 340 Brakes
320 Steering and Wheel Alignment
400 Body-General
410 Fenders, Engine Hood 411 Doors
412 Trunk Lid, Tailgate
510 Exterior Trim, Bumpers 512 Door Windows
Equipment 513 Interior Trim
7
Equipment and 720 seat Belts
Accessories 721 Airbag System (SRS)
OBD On-Board Diagnostics
. ............ ..
515 Central Lociting and
Anti-Theft
520 Seats 540 Sunroof
.................................................................... Foreword .............................. .. v
Index ................... .. ................................................................ rear of manual
Electrical
6 system
600 Electrical System-General 620 Instruments
610 Electrical Comoonent Locations 630 Liohts
611 wipers and washers 612 Switches eati in^ and Air Conditioning
Radio
. ........... ........ .........................
Electrical Wiring Diagrams

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Fuel Tank and Fuel pump/
- Remove suction hose from tank filler neck carefully to avoid
damaging filler neck baffle plate.
CAUTION-
After finishing repairs but before starling engine, be sure
there is at least
5 liters (1.5 gallons) of fuel in tanlc. The fuel
pump will be damaged if run without fuel.
Fuel tank, removing and installing
- Remove fuel tank filler cap and drain tank as described
earlier.
- Disconnect negative cable from battery.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove rear seat bottom cushion. Peel forward lip of carpet
from beneath seat cushion and carefully peel back insulation
to expose fuel tank access cover on left and right sides. Re-
move covers.
Disconnect right side supply hose and
electr~cal harness
connector (arrows).
D~sconnect left side return hose and electrical harness
connector.
Working inside car, disconnect parking
bralte cable ends
from parking brake lever. See
340 Brakes.
Lift car and support safely.
Make sure the car is stable and
we/ supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose. A floorjaclc is not adequate support.
- Remove complete exhaust system and heat shield. See 180
Exhaust System.
- Remove drive shaft. See 260 Driveshaft

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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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230-1 0
I Manual Transmission
Output shaft seal, replacing (5-speed
transmission) (transmission installed)
- Raise and safely support vehicle.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive
lilt orjack stands designed
for the purpose.
A floorjack is not adequate support.
- Remove exhaust system and heat shields. See 180 Exhaust
System
Support transmission with transmission jack.
Disconnect driveshafi at transmission output flange, and
hang driveshaft to side. See
260 Driveshaft.
Remove transmission crossmember:
If applicable, release electrical harnesses from transmis-
sion crossmember.
Remove transmission mounting bolts
(A).
Remove transmission crossmember bolts (6).
Where applicable, remove bolts (C).
- Tilt down rear of transmission.
CAUTIOI\C
Tilting the engine to lower the transmission can lead to
damage to various components due to lack of clearance.
4 Remove collar nut with BMW special tool (see table below) or
suitable thin-walled deep
socltet. Use BMW special tool
23 0 020 or equivalent to counterhold output flange.
Collar nut sockets
Transmission
BMW special tool
Getrag S5D 250G 23 1 21 0 (27 mm)
ZF S5D 3202 23 2 320 (36 mm)
Use puller (BMW special tool 33 1 150 or equivalent) to
remove output flange.
Use BMW special tool
00 5 010 or other suitable seal puller
to remove seal from transmission housing.

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230-1 1
Manual ~ransmissionl
Coat new seal with transmission fluid. Use seal installation
drift (see table below) to drive seal into position until it is flush
with housing.
Output seal drives
Transmission
BMW special tool
Getrag S5D 250G 240110
ZF S5D 3202 23 2 300
inspect sealing surface on output flange. Replace if flange
surface is worn or damaged.
Heat output flange to about 176"
F (80" C) to aid in installa-
tion. This can be done by placing flange in hot water. Rein-
stall output flange to output shaft.
- Coat flange nut with LoctiteB243 and reinstall. Torque in two
stages.
Tightening torques Output flange to output shaft
Stage I 190 Nm (140 ft-lb)
Stage II (after loosening) 120
Nm (89 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new nuts. See
260 Driveshaft.
Check transmission fluid level, topping up as necessary
Tightening torques Aluminum driveshaft to flex-disc
- MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
. MI0 (Torx bolt) 70
Nm (51 ft-lb)
. M8 (compression nut) 32
Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
- MI0 (8.8 grade) 48
Nm (35 ft-lb)
- MI0 (10.9 grade) 60
Nm (44 It-lb)
. MI2 (8.8 grade) 81 Nm (60 ft-lb)
. MI2 (10.9 grade) I00 Nm (74 It-lb)
M14 140 Nm (103 It-lb)
Transmission crossmember
- to transmission (ME) 21 Nm (15 It-lb)
- to chassis (M10) 42 Nm (30 It-lb)

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230-12
/ Manual Transmission
Output shaft seal, replacing (6-speed
transmission) (transmission installed)
- 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.
- Remove exhaust system and heat shields. See 180 Exhaust
System.
- Support transmission with transmission jack
- Disconnect driveshaft at transmission output flange, and
hang driveshaft to side. See
260 Driveshaft.
Remove transmission crassmember:
If applicable, release electrical harnesses from transmis-
sion crossmember.
Remove transmission and crossmember mounting bolts
(arrows).
5022305201 - Tilt down rear of transmission
CAUTION-
Tlting the engine to lower the transmission can lead to dam-
age to various components due to lack of clearance.
Use screwdriver to pry out output flange collar nut retaining
plate.
Remove collar nut with BMW special tool
23 2 320 or equiv-
alent thin-walled deep socltet
(36 mm). Use BMW special
tool
23 0 020 or equivalent to counterhold output flange.

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230-14
I Manual Transmission
If installing new output flange: Recalculate thickness of
shims based on difference in height between output shaft
surface and collar nut support surface. Shims must be within
the output flange preload specification below the collar nut
support surface.
Output flange preload Difference between heights of shaft and output 0.05
- 0.22 mm
flange sealing
suriace MINUS thickness of shims (0.002 - 0.009 in)
NOTE-
Shims are available in increasing sizes of 0.1 mm from
1.4 mm to 2.1 mm (0.055 in to 0.083 in) from BMWparts.
- Install shims. Install and torque flange collar nut.
Tightening torques Output flange to out put shaft
. Stage I 190 Nm (140 ft-lb)
. Stage II (after loosening) 120 Nm (89 it-lb)
- Use BMW special tool 23 2 470 to install flange nut retaining
plate.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new nuts. See
260 Driveshaft.
Checlc transmission fluid level, topping up as necessary.
Tightening torques
Aluminum driveshaft to flex-disc
- MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
MI0 (Tom bolt)
70 Nm (51 ft-lb)
M8 (compression nut) 32 Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
* MI0 (8.8 grade) 48 Nm (35 ft-lb)
- MI0 (10.9 grade) 60 Nm (44 ft-lb)
. MI2 (8.8 grade)
81 Nm (60 ft-lb)
MI2 (10.9 grade) 100 Nm (74 ft-lb)
- MI4 140 Nm (1 03 ft-lb)
Transmission
crossmembe~
to transmission (ME)
to chassis (M10)
21 Nm (15 ft-lb)
42 Nm (30 it-lb)

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--.
- - Manual Transmission
- V-8 engine: Remove heat shield from left front axle support.
< V-8 engine: Remove engine speed reference sensor from
transmission.
- Where applicable, remove brackets for transmission under-
body protection (adjacent to transmission).
4 Support transmission with transmission jack.
- Where applicable, remove reinforcing cross brace from
below driveshaft at transmission.
- Disconnect harness connector from back-up light switch
on transmission.
- Free harnesses for oxygen sensors and back-up lights
from crossmember and transmission.
Remove transmission crossmember: Remove transmission mount bolts
(A).
Remove transmission crossmember bolts (B)
Where applicable, remove bolts (C).
NOTE-
5-speed transmission shown in illustration. Crossmember
assembly for 6-speed transmission is similar.
Disconnect driveshaft from transmission and hang to one
side. See
260 Driveshaft.
I CAUTION- I
Do not damage constant velocity joint orprotective boot at
rear differential.
- 6-cylinder engine: Remove stabilizer bar links and swivel sta-
bilizer bar
u~wards.

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Manual Transmission
4 V-8 engine: Remove transmission mounting Tom-head bolts
(arrows). Note length and location of bolts.
Remove transmission by pulling backward until transmis-
sion input shaft clears clutch disc splines, then pull down-
wards. Lower transmission jack to remove transmission.
- Installation is reverse of removal, keeping in mind the
following:
When installing a new transmission, be sure to transfer
parts from old transmission
if applicable.
Thoroughly clean input shafl and clutch disc splines. Light-
ly lubricate transmission input shaft before installing.
* Be sure bellhousing alignment dowel sleeves are located
correctly. Replace damaged sleeves.
Center rear of transmission in driveshaft tunnel before
tightening transmission support bracket.
NOTE-
In order to avoid difficulties in transmission removal at a fu-
ture time, use washers with Torx-head mounting bolts.
- Reinstall driveshaft. Use new nuts when mounting driveshaff
to transmission/flex disc. See 260 Driveshaft.
- Refill transmission with appropriate lubricant before starting
or towing car. See Transmission fluid service earlier in this
repair group.

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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