Speed BMW 540i 1999 E39 Repair Manual

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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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230-12
/ 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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Manual Transmission
Input shaft seal, replacing
(transmission removed)
- Remove transmission from vehicle as described later in this
group.
- Remove clutch release bearing end release bearing lever
from inside bellhousing.
4 Remove bolts (arrows) for clutch release-bearing guide
sleeve, noting bolt lengths
(Getrag trensmission shown).
Remove sleeve and any spacers (shims) under it.
Two covered removal holes (arrows) are present in seal.
Thread BMW special tool
23 0 490 or equivalent slide ham-
mer seal puller into one hole and remove seal.
- Getreg S5D 250G transmission:
Place BMW special tool
23 2 460 or similar protective
sleeve over input shaft.
Coat sealing lip of new
seel with trensmission oil and push
over protective sleeve up to transmission housing.
Remove protective sleeve from input shaft.
Use BMW special tool
23 2 430 or similar drifl to drive seal
until fully seated.
- ZF S5D 3202 transmission:
Place BMW special tool
23 2 380 or similar protective
sleeve over input shaft.
Coat sealing lip of new seal with transmission oil and push
over protective sleeve up to transmission housing.
* Remove protective sleeve from input shaft.
Use BMW special tool
23 2 340 or similar drift to drive seal
until fully seated.
- 6-speed transmission:
Fit
cap of BMW special tool 23 2 492 over tool sleeve.
Coat sealing
lip of new seal with transmission oil and push
on tool sleeve. Remove tool cap from tool sleeve.
- Push sleeve with seal on input shaft.
- Use BMW special tool 23 2 491 or similar drift to drive seel
until fully seated.
Remove protective sleeve from input shaft.

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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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Automatic Transmission
Automatic transmission applications
Automatic transmissions are identified by code letters found
on a data plate located on the side or rear of the transmission
case. See table below for application information.
Automatic transmission applications
Model Year Engine Transmission
5281 to 911999 M52 A4S 310R
5281 from 911999
M52 TU A5S 360R
5251 to 312001 M54 A5S 390R
5251 from 312001 M54 ASS 3252
530i to 312001 M54
ASS 390R
530i from 312001 M54
A5S 3252
540i from 111997 M62
TU A5S 4402
Automatic transmission basic components
The automatic transmission fitted to BMW 5 Series models is
comprised of
3 main elements:
0 Torque converter capable of torque multiplication at an
infinitely variable ratio
Electrohydraulically controlled valve body
0 Gearbox containing 5 forward speeds and reverse

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240-6
I Automatic Transmission Automatic transmission fluid (ATF)
The E39 automatic transmission is filled with either Dexron Ill
ATF or Texaco 80728, a life time oil.
CA UTIOI\C
Use only the transmission fluid that is approved for use by
BMW All other fluids will cause non warrantable transmis-
I sion damage.
Mixing different types of transmission fluids will lead to
transmission failure.
NOTE-
The type of transmission lubricant used can be found on a
stickeron the transmission pan. Dexron
111ATF (blacksticker)
reads "ATF-Oil': Special life time oil (green sticker) reads
'Life-Time Oil': If in doubt, consult an authorized
BMW dealer
for alternate fluid use and current information regarding
transmission operating fluids.
ATF level, checking
Check ATF level if there is evidence of a leak, a complaint re-
lated to fluid level or afler transmission repairs.
The automatic transmission is not equipped with a dipstick.
Checking the ATF level requires that the transmission be at
operating temperature during the checking procedure.
NOTE-
Vehicle must be level throughout tests
- Drive vehicle to warm up ATF to operating temperature.
- Connect BMW diagnostic scan tool DiSplus, MoDiC, GTI or
equivalent to determine transmission oil temperature.
ATF level checking
Fluid temperature
30' - 50°C (85' - 120" F)
- With engine running, switch on air conditioning to increase
engine idle speed.
- Apply parking brake.
- While applying foot brake firmly move gear shift selector
lever through
all gear positions, pausing in each gear briefly.

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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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pearshift Linkage
~UTOMATIC TRANSMISSION
GEARSHIFT
Automatic transmission gearshift mechanism
automatic
5-speed Steptronic (5251,530i)
1. Shift lock solenoid
2. Shifter assembly
3. Shift cable
4. Support bracket
5. Selector lever
Gearshift mechanism, adjusting
(automatic transmission)
- Position gearshift lever in Park.
- Raise vehicle to gain access to shift linkage.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive
lift orjack stands designed for
the purpose.
4 Counterhold bushino A and loosen cable clam~ino nut 6.
Push cable end backward away from engine (arrow 2).
Release pressure on cable.
Tighten clamping nut.
/ CAUTION--
Tightening torque
Shift cable clamping nut
10 Nm (7.5 it-lb)

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250-7
Gearshift ~inka~el
Automatic shiftlock, checking function (automatic transmission)
The automatic shiftlock uses an electric solenoid to lock the
selector lever in Park or Neutral. Depressing the foot bralte
with the ignition on energizes the solenoid, allowing the lever
to be moved into a drive gear. The solenoid is energized only
when the engine speed is below 2,500 rpm and the vehicle
speed is below
3 mph (5 kph). The solenoid is mounted in the
right side of the selector lever housing.
... nir r
Shiftlock
4 Automatic shiftlock prevents drive gear selection until brake
pedal is depressed.
With engine running and car stopped, place selector lever
in Park or Neutral.
Without depressing bralte pedal, check that selector lever
is
loclted in position (Parlt or Neutral).
Depress brake pedal firmly. Solenoid should click audibly.
Check that selector lever can now be moved out of
Parlt or
Neutral.
parking
brake on and with extreme caution.
solenoid
0012713
With selector
lever in Park or Neutral and bralte pedal de-
pressed, raise engine above 2,500
rpm. Check that selec-
tor lever cannot be moved out of Park or Neutral.
If any faults are found check the electrical operation of the
shiftloclt solenoid and checlt for wiring faults to or from the
transmission control module (TCM). See
610 Electrical
Component Locations and ELE Electrical Wiring
Dia-
grams.
NOTE-
NOTE-
The solenoidis controlled via the TCM, using brake pedalpo-
sition, engine speed, and road speed as controlling inputs.
The
next test should be performed in an open area with the

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Suspension, Steering and Brakes - ~enerail
The main components of the system are the wheel speed
(pulse) sensors, the
ABSIASC or ABSIDSC control module,
and the hydraulic control unit.
Traction control also comes into operation during decelera-
tion. Decelerating on snowy or icy road surfaces can lead to
rear wheel slip. If a rear wheel starts to drag or lock up, the
ASC system can limit the problem by adjusting throttle, fuel
injection and ignition timing.
4 A switch (arrow) on the center console is used to toggle the
ASC on or off.
NOJE-
Even with the ASC system turned off, if the ASC control mod-
ule senses a difference in wheel speed (one wheel spinning)
the
ASC system applies modulated braling force to the slip-
ping wheel until traction is regained. There is no override of
fuelinjection function.
The ASC system is designed to be maintenance free. There
are no adjustments that can be made. Repair and trouble-
shooting of the ASC system requires special test equipment
and knowledge and should be performed only by an autho-
rized
BMW dealer.
ABSIASC traction
I 1.
control system
Wheel speed sensor
Wheel speed pulse wheel
Brake disk
Brake caliper
ABSIASC hydraulic unit
Brake master cylinder
Pedal operated throttle valve
ASC controlled throttle valve
Engine control module (ECM)
Accelerator pedal
ABSlASC control module