Reconditioning the gearbox on a BMW 5 Series E28 M535i involves several steps and requires a range of specialized tools and equipment. click here for more details on the download manual…..

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Below is a detailed guide presented in bullet points to help you through the process.

### Tools and Equipment Needed

– **Socket Set**: A comprehensive socket set including metric sizes is essential for removing bolts and nuts from the gearbox. Typically, you will need 10mm, 12mm, and 17mm sockets.

– **Wrenches**: A set of combination wrenches, particularly in metric sizes, to access areas where a socket may not fit.

– **Torque Wrench**: Necessary for reassembling the gearbox to ensure bolts are tightened to the manufacturer’s specified torque settings.

– **Screwdrivers**: A selection of Phillips and flat-head screwdrivers for various fasteners and components.

– **Pliers**: A pair of needle-nose and standard pliers for gripping and manipulating small components.

– **Gearbox Oil and Sealant**: replacing old oil with the appropriate gearbox oil is critical. Check the specifications for the E28 M535i to select the correct type. A high-quality sealant may also be required for gaskets.

– **Gasket Scraper**: To clean old gaskets off the surfaces of the gearbox before reassembly.

– **Magnet Tool**: Useful for retrieving any dropped nuts or bolts that may fall into hard-to-reach areas.

– **Work Light**: Ensures you have adequate illumination when working in tight or dimly lit spaces.

– **Parts Cleaner**: For cleaning internal components of the gearbox during disassembly.

– **Transmission Jack**: To support the gearbox during removal and reinstallation, making the process safer and easier.

– **Shop Manual or Service Manual**: A service manual specific to the BMW E28 M535i will provide crucial information on torque specifications, assembly procedures, and wiring diagrams.

### Procedure for Gearbox Reconditioning

– **Preparation**:
– Ensure the vehicle is parked on a flat surface with the engine off and cooled down.
– Disconnect the battery to avoid any electrical issues while working.

– **Remove the Driveshaft**:
– Unbolt the driveshaft from the gearbox and carefully slide it out of the way. Use a marker to note the position for reinstallation.

– **Disconnect Gear Linkage**:
– Detach any gear linkage components. This often involves removing clips or bolts that secure the linkage to the gearbox.

– **Support the Gearbox**:
– Position the transmission jack under the gearbox to support it while unbolting. This is crucial for safety.

– **Unbolt the Gearbox**:
– Remove the bolts securing the gearbox to the engine block. Keep track of these bolts, as they may vary in length.

– **Remove the Gearbox**:
– Carefully lower the gearbox from the engine using the transmission jack. Take your time to maneuver it out without damaging any surrounding components.

– **Disassemble the Gearbox**:
– Once on a workbench, begin disassembling the gearbox. Remove the outer casing by unscrewing the bolts. Keep track of the order and placement of parts.
– Inspect and document the condition of gears, synchros, and bearings.

– **Clean Components**:
– Use a parts cleaner to thoroughly clean all components of the gearbox. Pay special attention to the gears and any areas where dirt may have accumulated.

– **Replace Worn Parts**:
– Identify any worn or damaged components such as bearings, seals, or synchros. Replace them with OEM or high-quality aftermarket parts.

– **Reassemble the Gearbox**:
– Apply a new gasket or sealant as required. Reassemble the gearbox in the reverse order of disassembly, ensuring all components are fitted correctly.

– **Torque Specifications**:
– Use the torque wrench to tighten all bolts to the manufacturer’s specifications as outlined in the service manual.

– **Reinstallation**:
– Lift the gearbox back into position under the vehicle, using the transmission jack. Align it with the engine and secure it with the original bolts.

– **Reconnect Driveshaft and Gear Linkage**:
– Reconnect the driveshaft to the gearbox and secure any gear linkage components.

– **Fluid Replacement**:
– Fill the gearbox with the appropriate type and amount of lubricant as specified in the service manual.

– **Final Checks**:
– Reconnect the battery and perform a final inspection to ensure all tools and parts are accounted for.
– Start the vehicle and test the gearbox operation, ensuring smooth shifting through all gears.

### Conclusion

Reconditioning the gearbox of a BMW 5 Series E28 M535i is a detailed process that requires careful attention to detail and the right tools. By following these steps and ensuring proper reassembly and fluid replacement, you can restore the functionality of the gearbox and ensure the longevity of your vehicle’s transmission system. Always consult the service manual for your specific model for additional guidance and specifications.
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