M/T - 3rd or 4th Gear Difficult to Engage

GROUP 23
Manual Transmission

Bulletin Number
23 01 95 (4254)

Woodcliff Lake, NJ
May 1996
Product Engineering

This Service Information Bulletin supersedes S.I. 23 01 95 (4254) dated July 1995; please remove it from your S.I. binder and discard.

SUBJECT:
3rd and 4th Gear Difficult to Disengage/Engage

MODELS:
E36 - M3 with S5D 310Z transmission
E34 - 530i with S5D 310Z transmission

Complaint:
Difficult to disengage 3rd gear and engage 4th gear.

Correction:
In case of customer complaint, replace the lock pin associated with 3rd/4th gear if the transmission's serial number is within the range 231501-334553.

The 3rd/4th gear lock pin can be replaced without removing the transmission by using special tool 90 88 6 233 100 (see procedure). All dealers will receive the special tool through the automatic tool shipment program.





Parts Information:





Warranty Information:
Parts and labor will be reimbursable under the terms of the applicable BMW New Car Limited Warranty.

Procedure:
Replacement of lock pin 3rd/4th gear on S5D 310Z transmissions.

The illustrations in this procedure show the transmission removed for reference purposes only. It is not necessary to remove the transmission to complete this repair.





1. The repair kit P/N 23 311 222 992 contains:

(1) Collar bush

(2) Lock pin

(3) Spring

(4) Cap





2. Screw special tool 23 3 102 into tool 23 3 101 until two threads are exposed.





3. Clean the transmission casing in the area of the lock pin (see arrow), to prevent dirt from falling into the transmission while the pin is being removed.





4. Remove the exhaust support bracket attached to the transmission casing.





5. Place tool 23 3 101 on the transmission casing making certain that the tip of 23 2 102 is properly seated in the cap which holds the lock pin in place. Make certain that the tool is flush with the casing and that the tightening bolt rests on the portion of the casing to which the exhaust bracket was attached.

Pull the tool down as far as possible using the tightening bolt.

Tighten special tool 23 3 102, 2-3 full turns using a short 17 mm wrench.





6. Loosen the tightening bolt on tool 23 3 101 as much as possible. Hit the base of tool 23 3 101 with a plastic mallet forcing the tool to move upwards and pull out the cap.





7. Remove the spring (A) using special tool 23 3 106.





8. Remove the lock pin using special tool 23 3 106.





NOTE:
It may be necessary to loosen the lock pin by moving the pin back and forth using special tool 23 3 107.

Reassemble





9. Screw special tool 23 3 103 into tool 23 3 101.

Apply small amount of grease to special tool 23 3 103 and attach the collar bush to the tool.

Check the alignment of the slit as the collar is attached





10. Place the collar bush on the borehole for the lock pin using tool 23 3 101 making certain that the collar is properly seated in the hole. Make certain that the tool is flush with the casing and that the tightening bolt rests on the portion of the casing to which the exhaust bracket was attached.

Tighten the tightening bolt and insert the collar as far as it will go.

Loosen the tightening bolt and remove special tool 23 31 01.

Use a mirror to check that the collar is inserted correct and that it is flush with the casing.





11. Insert the lock pin (2) and spring (3) into the borehole.





12. Screw special tool 23 3 104 into tool 23 3 101.

Apply a small amount of grease to special tool 23 3 104 and attach the cap (4) to the tool.





13. Place the cap into the borehole of the lock pin using special tool 23 3 101 making certain that the cap is properly seated in the hole. Make certain that the tool is flush with the casing and that the tightening bolt rests on the portion of the casing to which the exhaust bracket was attached.

Tighten the tightening bolt and insert the cap as far as it will go.

Loosen the tightening bolt and remove special tool 23 31 01.

Use a mirror to check that the cap is seated correctly.

14. Screw special tool 23 3 105 into tool 23 3 101.





15. Place the triangular shaped tool into the borehole of the lock pin, on top of the cap using special tool 23 3 101 making certain that the tool is properly seated in the hole. Make certain that the tool is flush with the casing and that the tightening bolt rests on the portion of the casing to which the exhaust bracket was attached.

Tighten the tightening bolt and insert the cap as far as it will go.





Loosen the tightening bolt and remove special tool 23 31 01.





16. Use a mirror to inspect the cap seal.