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DIY: Do It Yourself
Post here to share or improve your wrench turning skills! All BMW E46 DIY tips, tales, and projects discussed inside. Learn to work on your car and know the right BMW parts you will need!

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Old 08-25-2013, 03:43 AM   #1
lowrider
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Arrow ||DIY|| How to Rebuild a 5-Speed Transmission -- THE REAL DEAL

Let's start off with a little background. 7 years ago I bought my 2000 323ci used with 124k miles on the clock. I drove straight to the doctor who informed me I had the "mod-bug" and that there was no cure.

All joking aside, I have absolutely loved every minute of owning and wrenching on my BMW. For a while I even ran a small business through E46Fanatics where I worked on fellow fanatics' cars. But, when my car reached (well almost) the 200k mile mark, I decided it was time for some major maintenance. The car was leaking from almost every place possible which had created a thick film of sludge over the entire engine and transmission as well as most of the underbody.

On July 4, 2013 I pulled the engine and transmission out and began to address problem areas. I had never intended on rebuilding the transmission (was crossing my fingers that it was OK) but sadly there was significant axial play in the shafts which indicated bad bearings. I will soon post about my entire rebuild, but this thread should serve to detail and demystify how to disassemble/reassemble a 5-speed transmission (Getrag S5D-250G)

I know I took plenty of photos of the disassembly, but for the life of me I cannot find them. The photos below should help though if you run them in reverse. Here is a link to the ONLY information I was able to find on how to get a Getrag apart (http://www.bmw-m50.com/transmission/getrag-250g/)


DISASSEMBLY


The Bentley manual should be able to get you this far.

The liberated and filthy engine/trans:

 photo 20130707_180821_zpsc068592b.jpg

 photo 20130707_180827_zpse2c01491.jpg

Disassembly steps that I don't have pictures of:

Remove the 9 bolts holding the two halves together (13mm)
Remove output shaft flange (30mm, use impact)
Remove output shaft seal (screw driver and pliers or seal puller)
Remove selector shaft seal (screw driver and pliers or seal puller)
Remove reverse gear bolt on bell housing side (13mm socket, directly below where slave cylinder mounts)
Remove reverse switch (19mm)
Remove throwout bearing sleeve (10mm, inside bell housing)
Remove input shaft seal (screw driver and pliers or seal puller)
Remove snap ring and support ring (my snap ring was not tool removable so I torched it and bent it until it came out)

I then made a tool out of pipe material to separate the two halves. I machined the pipe flange to pick up the bolt circle inside the bell housing. Connect a three jaw puller and you should be able to separate the two halves. BE CAREFUL!!! There is a pin that must be removed after you start pushing the two halves apart, but before you get too far.

 photo IMG_3619_zpsf0cfaccc.jpg

 photo IMG_3620_zps40266831.jpg

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To remove the main shaft and counter shaft (guts) of the transmission, simply turn the casing over so that you can set the case flat inside a press. Don't forget to remove all the detent balls and pins (see link above). Then press on the output shaft until it rains gears and shafts (prepare a soft landing for the parts).

From here I put everything into a parts washer for a couple days. I was surprised to find that my 5th gear synchronizer ring was almost completely destroyed. Don't know how I was getting into 5th, but by then you are almost turning at engine speed anyways.

 photo 20130709_232625_zps6ecf1796.jpg


ASSEMBLY

After a month waiting on parts to come in from Germany, finally ready to go!

 photo IMG_3563_zps729e1dd6.jpg

I managed to lose the detent balls/plates/springs for my 1st/2nd gear selector so I ordered new parts from BMW, but they wont sell you the springs...you have to buy the whole gear selector for some ungodly expensive cost. So, if you need replacement springs check out www.centryspring.com (P/N: FF-2).

 photo IMG_3559_zps3d7f9c8b.jpg

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Press in the input shaft bearing

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Press in the output shaft bearing

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Old 08-25-2013, 03:44 AM   #2
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Install new 5th/Reverse resistance springs (long, softer one on top, short, stiffer one on bottom). Point reliefs toward each other.

 photo IMG_3573_zpsc8d6132f.jpg

 photo IMG_3576_zps2bc9fc92.jpg

Install input shaft bearing retainer (7 ft-lb)

 photo IMG_3577_zps7b0f3daf.jpg

Install arm and wheel

 photo IMG_3578_zps43233d65.jpg

Assemble pivot, spring, and sleeve

 photo IMG_3580_zps62836330.jpg

Install the assembly (pivot bolts in from front and top, 7 ft-lb)

 photo IMG_3581_zpsb9ce252d.jpg

 photo IMG_3583_zpsa4a84137.jpg

 photo IMG_3584_zpsfaeee9a8.jpg

Install output shaft bearing retainer (7 ft-lb)

 photo IMG_3585_zps5ab88e4a.jpg

Install new 5th gear synchro (Green grease is lubricant that will help with break-in that dissolves in transmission fluid and also helps to keep components in place during assembly. YOU WILL NEED THIS STUFF, it is called "Assemblee Goo")

 photo IMG_3586_zps149d53c4.jpg

 photo IMG_3587_zps491eb319.jpg

Install counter shaft roller cage

 photo IMG_3588_zps1c04b6cf.jpg

Mate the main and counter shaft and install all 3 gear selector rods. You will also need to insert the detent pin into the middle gear selector rod and use assemblee goo to keep in place. (I tried to be clever and zip tie it all together but it turned out that it was not necessary)

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Install the assembly into the rear case. Align the counter shaft bearing and all gear selector shafts.

 photo IMG_3593_zps3b95c13d.jpg

 photo IMG_3596_zps543b963f.jpg

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You will need to drop the counter shaft bearing retainer into the transmission and fish it into place because it bolts in from the outside (Patience Required!)

 photo IMG_3604_zps54bda72c.jpg

Bolt in the counter shaft bearing retainer (7 ft-lb)

 photo IMG_3603_zps0ffce9f0.jpg
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Old 08-25-2013, 03:45 AM   #3
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Install detent ball/pins/springs

 photo IMG_3605_zps88703211.jpg

 photo IMG_3606_zps753dc95c.jpg

Install reverse gear (Tighten by ratchet until fairly snug). I also chose to apply a RTV to the seal surface.

 photo IMG_3622_zps5169fd2f.jpg

 photo IMG_3623_zps458dd848.jpg

A picture is missing here, but before you slide the bell housing back on, you need to insert one more short shaft (~5" long) into the right hand side of the rear case. Place the lever into the groove on the short shaft and the groove on the 5th/Reverse gear selector shaft. Use assemblee goo to hold it into place.

 photo IMG_3624_zps1eb96bb0.jpg

Turned a special tool for pressing the two halves back together. This ensures that only the input shaft bearing is pressed against and NOT the bell housing.

 photo IMG_3626_zpsc8696b0a.jpg

 photo IMG_3625_zpsab39074a.jpg

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Press the main shaft through the input shaft bearing until the hole in the pivot piece and lever line up. This will take some "fiddling" to get right. When the holes line up, insert the pivot pin.

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Bolt cases together (no torque value given, but I went to 17 ft-lb).

 photo IMG_3657_zps72082414.jpg

 photo IMG_3658_zpsefd9c9b6.jpg

Reinstall the reverse switch (19mm, 13 ft-lb). Bolt in the reverse gear on the bell housing side, again there is no given torque value, so just snug it up (picture missing).

 photo IMG_3635_zpse4f8e7cd.jpg

 photo IMG_3636_zps83b21d85.jpg

Install input shaft bearing support ring and snap ring

 photo IMG_3637_zps52523d71.jpg

 photo IMG_3638_zpsf81e46ba.jpg

 photo IMG_3640_zpsed31d212.jpg

Install new input shaft seal (Apply coating of transmission fluid). Used special tool from before.

 photo IMG_3641_zps31c0f961.jpg

 photo IMG_3642_zps37166047.jpg

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Install throwout bearing sleeve (7 ft-lb)

 photo IMG_3644_zpsc102716b.jpg

 photo IMG_3645_zps5b7e511a.jpg

Install output shaft seal (Apply coating of transmission fluid). Can be drawn in using output flange and nut.

 photo IMG_3646_zpsf57d1c7f.jpg

 photo IMG_3647_zpsebda3bf0.jpg

 photo IMG_3648_zpse2c95220.jpg
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Old 08-25-2013, 03:45 AM   #4
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Tighten output flange nut, apply Loctite to threads (140 ft-lb, then break free, then 89 ft-lb).

 photo IMG_3649_zpsdeefda2a.jpg

 photo IMG_3650_zps6184d7e5.jpg

Install selector shaft seal (Apply coating of transmission fluid).

 photo IMG_3651_zps31c808e6.jpg

 photo IMG_3652_zpsd5f75c25.jpg

 photo IMG_3653_zpsf8d90987.jpg

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Install shift rod joint

 photo IMG_3655_zpsdf155446.jpg

 photo IMG_3656_zps3cf52780.jpg

Fill her up with fluid, I chose Royal Purple 75w-90 (Plug, 37 ft-lb)

 photo IMG_3662_zps03fc3cef.jpg

 photo IMG_3663_zps51817db9.jpg

 photo IMG_3664_zps62631d73.jpg

ALL FINISHED

 photo IMG_3665_zpsf13882eb.jpg

Video my brother took of me running through the gears:




All in all, I would rate this as a 10 out of 10 for difficulty. I definitely want to thank my brothers for helping me out even when we got extremely frustrated at the trans. The job required many expensive and special tools to complete. This job took me about 30 hours to complete, although now I feel like I could do it in 1/3 the time. I probably had to split the cases close to 10 times before I figured out how to do it just right. I spent about $500-600 to rebuild a transmission that would have cost me more than $2000 if I sent it in, so I am still ahead by a lot.

Hope you enjoyed looking and that I might have helped in some way if you are considering this job yourself. Will offer tool rental if anyone wants.
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Old 08-25-2013, 06:25 AM   #5
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DIY Extreme good work. how does it feel/shift back in the car?
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Old 08-25-2013, 01:36 PM   #6
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Nice work. I can appreciate the time and dedication that went into this. The tools make all the difference too. Job well done!
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Old 08-25-2013, 03:46 PM   #7
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Holy crap, I am impressed!
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Old 08-25-2013, 06:42 PM   #8
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Nice write up
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Old 08-25-2013, 07:27 PM   #9
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Re: ||DIY|| How to Rebuild a 5-Speed Transmission -- THE REAL DEAL

Amazing work!


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Old 08-25-2013, 11:11 PM   #10
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Small update: Machined a new clutch lever pivot pin out of aluminum to replace the factory plastic one.

 photo IMG_3686_zpsffcce5c7.jpg

 photo IMG_3687_zps7b2b504e.jpg

 photo IMG_3688_zpsadb8ac2a.jpg

 photo IMG_3689_zps6e0c62f3.jpg


New clutch, pressure plate, flywheel, SSK, and SS clutch line in the mail. Should be able to drop the engine/trans in this weekend. Back on the road soon
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Old 08-26-2013, 11:40 PM   #11
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You should ask mods if they can relocate this thread to "General E46" or DIY. It may not get the traffic it deserves in Showroom.
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Old 08-27-2013, 12:38 AM   #12
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Quote:
Originally Posted by TitaniumCranium View Post
You should ask mods if they can relocate this thread to "General E46" or DIY. It may not get the traffic it deserves in Showroom.
Looks like that got handled for me. But you're right, I have noticed a decline in activity on this forum. Not nearly what it used to be 3 or 4 years ago. I guess everybody is driving e90's now.

Clutch/flywheel should be here tomorrow!
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Old 08-27-2013, 12:52 AM   #13
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wow this was absolutely amazing.
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Old 08-28-2013, 06:44 PM   #14
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Very nice job, it compliments my 5L40E DIY nicely. Now we just need another good ZF and we would be all set! All but the damn Getrag 226 M3 6 speed that they wont sell parts for.
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Old 08-28-2013, 07:53 PM   #15
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Quote:
Originally Posted by Aedion View Post
wow this was absolutely amazing.
Thanks!

Quote:
Originally Posted by ddaniel1 View Post
Very nice job, it compliments my 5L40E DIY nicely. Now we just need another good ZF and we would be all set! All but the damn Getrag 226 M3 6 speed that they wont sell parts for.
Yea I saw your DIY, holy crap what a lot of work for an auto. You did a great job of identifying all the details

You can't get Getrag 226 stuff from Germany through getBMWparts?
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Old 08-28-2013, 08:10 PM   #16
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Thanks!



Yea I saw your DIY, holy crap what a lot of work for an auto. You did a great job of identifying all the details

You can't get Getrag 226 stuff from Germany through getBMWparts?
That is what I have read, no parts sold to the public outside of some external stuff, I hope I am wrong, I have one that may need rebuilt.
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Old 08-28-2013, 08:40 PM   #17
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Quote:
Originally Posted by ddaniel1 View Post
That is what I have read, no parts sold to the public outside of some external stuff, I hope I am wrong, I have one that may need rebuilt.
Wow ya, checked realoem and there is nothing there besides the stuff you said. Looks like I got lucky then.
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Old 08-28-2013, 09:24 PM   #18
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I am trying a new quality shifter this weekend, hopefully it cures an intermittent not wanting to go into gear problem, if I have to replace the tranny I will definitely attempt the rebuild.
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Old 08-29-2013, 07:42 AM   #19
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Re: ||DIY|| How to Rebuild a 5-Speed Transmission -- THE REAL DEAL

Wow this is an ultimate DIY.

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Old 08-30-2013, 02:22 AM   #20
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Small update: received the clutch kit from gripforce (trying them out). Waiting on orders from ECS and UUC to finish the car.

Went with the carbon/kevlar option:

 photo IMG_3707_zps4df09b7e.jpg

 photo IMG_3708_zpsdab6bc4f.jpg

 photo IMG_3709_zps62fb6a63.jpg

 photo IMG_3710_zps3021852a.jpg

Not cleaned up yet
 photo IMG_3711_zpse1f544f5.jpg

 photo IMG_3712_zps2d3dcb22.jpg

 photo IMG_3713_zps1000ce08.jpg

 photo IMG_3714_zps9fc679e2.jpg

Pilot bearing puller rental from AutoZone made the job a breeze

 photo IMG_3718_zpsb28c3fa3.jpg

 photo IMG_3719_zpsbed5938f.jpg

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The new pilot bearing can be installed with a dead-blow hammer to start

 photo IMG_3725_zps3294aea2.jpg

 photo IMG_3726_zpsc88a29d7.jpg

Then use a socket or equivalent push rod to land it on the shoulder

 photo IMG_3727_zps4141c9e0.jpg

Use the supplied bolts, apply some Loctite, torque to 80 ft-lbs (was getting conflicting values of 77 and 85 ft-lbs from online sources so I chose 80. No torque value given in the Bentley manual)

SMFW-FTW!

 photo IMG_3728_zps2710a418.jpg


More to come later...
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