A/T - M Double Clutch Transmission Replacement
SI B28 04 08Double-Clutch Transmission with Drivelogic
November 2008
Technical Service
This Service Information bulletin supersedes SI B24 08 06 dated July 2008.
[NEW] designates changes to this revision
SUBJECT
M Double-Clutch Transmission with Drivelogic Transmission Replacement Procedure
MODEL
E90, E92, E93 M3 with S65 and M DCT transmission
SITUATION
The current version of BMW TIS does not contain the M DCT (GS7D36SG) transmission removal (replacement) procedure.
Use the following procedure when M DCT transmission replacement is required.
IMPORTANT:
The M Double-Clutch Transmission (DCT) requires a special lubricant/hydraulic fluid: DCTF-1 Pentosin (P/N 83 22 2 147 477). This fluid is specific to the double-clutch transmission and should not be substituted with any other product.
Substituting the DCTF-1 Pentosin in M Double-Clutch Transmission (GS7D36SG) may cause a significant damage to the internal clutches of the transmission assembly, requiring replacement of the complete gearbox, transmission oil cooler, and cooler lines.
The BMW DCTF-1 Pentosin fluid does not require regular service. It is an extended-life type of fluid and should not be replaced. Currently the fluid is in extremely short supply, and can be obtained only after a PuMA case is submitted to the TeileClearing (Enhanced Technical Support). Refer to SI B28 02 08 (May 2008) for more information related to M DCT TeileClearing.
1. The vehicle needs to be placed and secured on the appropriate workshop lift. Disconnect the battery; remove the underbody transmission cover, front reinforcement plate, complete exhaust system and drive shaft.
NEW 2. Remove the M5 screw (1) from the hydraulic lines bracket.
3. Disconnect the connectors (2) for the crankshaft and oil level/quality sensors.
4. Remove the wiring harness for the oxygen sensors (3) from its mounting plate.
5. Remove three T30 screws (1) and the oxygen sensors support bracket (2).
[NEW]
6. Remove four M10 bolts (1), using the E12 socket.
NOTE:
When reinstalling, torque them to 38 Nm.
7. Remove the M5 screw (2), and remove the speed sensor connector (3).
[NEW]
8. At the rear right side of the transmission, locate the parking lock assembly cable.
9. Remove the Torx screw Allen 5 mm (1), and pull the parking lock cable (2) away from the parking lever.
[NEW]
10. Locate the oil cooler thermostat at the upper left (driver) side of the transmission.
11. Remove the M8 screw (1), using the E10 socket at the oil cooler thermostat.
12. Carefully disconnect the cooler lines (2), collecting all spilled DCTF-1 transmission fluid.
NOTE:
When reinstalling the cooler lines, the two o-rings between the lines and cooler thermostat need to be replaced. Use P/N 17 21 1 742 636.
13. Use the appropriate transmission stand to support the DCT transmission during removal. BMW recommends the Universal Transmission Stand, P/N 83 30 0 490 133 (Cartool P/N 00 2 030), with the adapter P/N 83 30 0 495 498 (Cartool P/N 23 4 050).
14. Install the special tool P/N 83 30 0 496 269 (Cartool P/N 11 9 990) to prevent excessive engine tilt when the transmission is removed.
15. Position the tool's bracket at the right (passenger) side of the front cross member, and secure it with the bolt (1).
16. The other bolt (2) should be adjusted to the length of A=50 mm, measured between the bracket's surface and the plastic tip (end). The plastic end of the screw (2) should be touching the housing of the belt tensioner when installed correctly.
Clearance between the top of the front cross member support and the base of the belt tensioner should be A=50 mm (proper adjustment for special tool P/N 0 496 269).
17. Remove the transmission's rear bracket support.
18. Remove the M10 bolt (1) and the oil cooler's thermostat (2).
19. Carefully lower the transmission until the M10 bolts at the upper part of the bell housing are accessible.
20. Remove six M10 bolts (1), using the E13 socket.
21. Remove two longer M10 bolts (2).
NOTE:
When reinstalling, torque the M10 bolts to 38 Nm.
22. When sufficient clearance is obtained at the top of the transmission, disconnect the Mechatronic harness connector (1) by first turning it counter-clockwise and then pulling it out.
NOTE:
Make sure not to stretch the Mechatronic harness during the gearbox removal, which may loosen the female pins in the harness connector.
23. Remove both screws (1) securing the oil cooler.
24. Carefully slide the oil cooler out of the guide bracket (2).
NOTE:
Do not rotate the oil cooler when removing it from its bracket. The plastic guides may be damaged.
WARRANTY INFORMATION
For information only
Disclaimer