Replacing the gearbox (transmission) in a BMW 135is E82 1 Series Coupe is a complex task that requires mechanical knowledge, the right tools, and safety precautions. click here for more details on the download manual…..
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Below is a detailed guide on how to perform this replacement, including descriptions of key components involved in the process.
### Tools and equipment Needed:
1. **Basic Hand Tools:**
– Socket set (metric)
– Wrenches (metric)
– Screwdrivers (flathead and Phillips)
– Torque wrench
– Pliers
– Hammer (rubber mallet recommended)
2. **Specialized Tools:**
– Transmission jack or a standard jack with a stable platform
– Engine support brace (if necessary)
– Alignment tool (for clutch alignment, if applicable)
3. **Safety Equipment:**
– Safety goggles
– Gloves
– Steel-toed boots
4. **Replacement Parts:**
– New gearbox (OEM or suitable aftermarket)
– New transmission fluid
– New input and output shaft seals
– New clutch kit (if applicable)
– New flywheel (if applicable)
– New pilot bearing (if applicable)
### Procedure:
#### Step 1: Preparation
1. **Disconnect the Battery:**
– Open the hood and disconnect the negative terminal of the battery to ensure safety while working on the vehicle.
2. **Lift the Vehicle:**
– Use a hydraulic jack to lift the front of the car and secure it on jack stands. Ensure the vehicle is stable and secure.
#### Step 2: Remove the Drive Shaft
1. **Locate the Drive Shaft:**
– The drive shaft is connected to the gearbox and the rear differential.
2. **Disconnect the Drive Shaft:**
– Use a socket to loosen and remove the bolts securing the drive shaft to the gearbox and the differential.
– Carefully slide the drive shaft out of the gearbox and set it aside.
#### Step 3: Remove the Exhaust System (if necessary)
1. **Locate the Exhaust Components:**
– Depending on the model and configuration, you may need to remove portions of the exhaust system to access the gearbox.
2. **Unbolt the Exhaust:**
– Remove the bolts connecting the exhaust to the downpipe and any hangers that secure it to the vehicle.
#### Step 4: Remove the Gearbox
1. **Support the Gearbox:**
– Use a transmission jack to support the weight of the gearbox.
2. **Disconnect Electrical Connectors:**
– locate and disconnect any electrical connectors attached to the gearbox.
3. **Remove the Gearbox Mounting Bolts:**
– locate the gearbox mounting bolts (usually found on the bell housing). Remove these bolts using the appropriate socket.
4. **Remove the Gearbox:**
– Carefully slide the gearbox away from the engine. You may need to rotate it slightly to clear any obstructions.
#### Step 5: Install the New Gearbox
1. **Prepare the New Gearbox:**
– Ensure that the new gearbox is clean and inspect it for any damage. Replace seals as necessary.
2. **Align and Insert the New Gearbox:**
– Using the transmission jack, position the new gearbox in place. Ensure that it aligns properly with the engine and that the input shaft fits into the pilot bearing (if applicable).
3. **Secure the Gearbox:**
– Reinstall the gearbox mounting bolts and tighten them to the manufacturer’s torque specifications.
#### Step 6: Reconnect Components
1. **Reattach the Drive Shaft:**
– Slide the drive shaft back into the gearbox
and secure it with the bolts. Ensure it is properly aligned.
2. **Reconnect the Exhaust System:**
– If you removed any parts of the exhaust, reattach them securely.
3. **Reconnect Electrical Connectors:**
– Reconnect any electrical connectors that were detached during the removal process.
#### Step 7: Fill the Transmission with Fluid
1. **Locate the Fill Plug:**
– Find the fill plug on the side of the gearbox.
2. **Add Transmission Fluid:**
– Using a funnel, add the appropriate type and amount of transmission fluid as specified in the owner’s manual.
#### Step 8: Final Checks
1. **Reconnect the Battery:**
– Reconnect the negative terminal of the battery.
2. **Test the Vehicle:**
– Start the engine and check for any unusual noises or leaks. Ensure that the gearbox shifts smoothly.
3. **Lower the Vehicle:**
– Carefully remove the jack stands and lower the vehicle.
### Conclusion
Replacing the gearbox in a BMW 135is E82 1 Series Coupe is a labor-intensive process that requires careful attention to detail. Ensure that you have all necessary tools and parts before beginning the process. If you’re not comfortable performing this task, it may be best to consult a professional mechanic. Always refer to the vehicle’s service manual for specific torque specifications and additional instructions.
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