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Manual Transmission Output Shaft Seal Replacement
 
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Pelican Technical Article:

Manual Transmission Output Shaft Seal Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$150

Talent:

*****

Tools:

18mm socket and wrench, flathead screwdriver, E12, 30mm socket, seal puller, 3-jaw puller, floor jack, two jack stands, two wheel chocks, safety glasses, torque wrench

Applicable Models:

BMW 525i/xi Sedan (2004-07)
BMW 528i xDrive Sedan (2009-10)
BMW 528i/xi Sedan (2008-10)
BMW 530i/xi Sedan (2004-07)
BMW 530xi Wagon (2006-07)
BMW 535i xDrive Sedan/Wagon (2009-10)
BMW 535i/xi Sedan (2008-10)
BMW 535xi Wagon (2008)
BMW 545i Sedan (2004-05)
BMW 550i Sedan (2006-10)

Parts Required:

Manual transmission fluid, output shaft seal

Hot Tip:

Warm transmission for three miles before beginning

Performance Gain:

Remedy a fluid leak

Complementary Modification:

Replace manual transmission fluid

The longitudinally installed BMW E60 drivetrain came with a choice of three styles of 6-speed transmission: Manual with foot-operated clutch; sequential manual with automatic clutch (SMG); automatic (Steptronic).

In rear-wheel drive models the driveshaft bolts directly (via a flex-disc) to the transmission output shaft. All-wheel drive (xDrive) models are equipped with a transfer case bolted to the rear of the transmission. The transfer case rear output shaft attaches to the rear driveshaft via flex-disc. The front driveshaft is equipped with two universal joints and bolts to the front output shaft of the transfer case.

On the manual transmission in a rear-wheel drive car, the output shaft seal can leak over time as the sealing lip wears. You may notice a leak toward the rear of your transmission. Be sure to check the shift selector shaft seal as well. See our tech article on manual transmission selector shaft seal replacing. When looking for the source of an oil leak, always look for fresh, clean oil. This will direct you to the problem area. If you see dirt gathered around the output shaft seal and a clean oily area, this indicates a leak at the seal. I would suggest replacing your transmission fluid when you replace this seal.

In this article, I'll go over the steps involved with replacing the driveshaft output shaft seal on rear-wheel drive BMW E60 models with a manual transmission.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Jack up your vehicle and support it using jack stands. See our tech article on jacking up your vehicle.

Remove the transmission splash shields. See our tech article on engine splash shields removing.

The seal is tucked away behind the flex-disc and transmission cross member.
Figure 1

The seal is tucked away behind the flex-disc and transmission cross member. If checking for a leak, look to the front of the cross member. Inspect the tail shaft of the transmission for signs of fresh oil.

Place a screw jack or hydraulic jack under the rear muffler (red arrow).
Figure 2

Place a screw jack or hydraulic jack under the rear muffler (red arrow).

Working at the center muffler hanger, behind the fuel tank (green arrow), lever the rubber hanger off the support using a pry bar (red arrow).
Figure 3

Working at the center muffler hanger, behind the fuel tank (green arrow), lever the rubber hanger off the support using a pry bar (red arrow).

Next, move forward on the exhaust to the center reinforcement (green arrow).
Figure 4

Next, move forward on the exhaust to the center reinforcement (green arrow). Remove the four 13mm fasteners (red arrows). Then remove the reinforcement from the body.

Now it is time to remove the final few supports for the exhaust and lower it.
Figure 5

Now it is time to remove the final few supports for the exhaust and lower it. First move to the rear of the muffler and remove the two 13mm nuts (red arrows).

Then remove the rear most hanger fastener (red arrow), a 13mm nut located to the left side of the tail pipe (green arrow).
Figure 6

Then remove the rear most hanger fastener (red arrow), a 13mm nut located to the left side of the tail pipe (green arrow).

Working at the transmission cross member, remove the E10 bolts while counter-holding the 13mm nuts (green arrows).
Figure 7

Working at the transmission cross member, remove the E10 bolts while counter-holding the 13mm nuts (green arrows). Note the bushing position when removing (red arrows) for reinstallation.

Lower the jack supporting the muffler about eight inches.
Figure 8

Lower the jack supporting the muffler about eight inches. Then remove the center heat shield fasteners (red arrows). There are eleven 8mm fasteners.

Once the fasteners have been removed, rotate the center heat shield toward the right side of the vehicle and pull it out from above the exhaust toward the rear of the vehicle (red arrow) and remove it.
Figure 9

Once the fasteners have been removed, rotate the center heat shield toward the right side of the vehicle and pull it out from above the exhaust toward the rear of the vehicle (red arrow) and remove it. At the front most corners of the heat shield, there are folded retaining tabs. Reach up under the plastic body shielding and unclip them.

Now move forward to the front pipe heat shield.
Figure 10

Now move forward to the front pipe heat shield. Remove the three 8mm fasteners (red arrows) and two 10mm sheet metal nuts (green arrows).

Once the heat shield is free, move it down away from the body and toward the rear of the vehicle.
Figure 11

Once the heat shield is free, move it down away from the body and toward the rear of the vehicle. This one can stay in the vehicle if you want. You will have enough room to work around it.

Place a screw jack or hydraulic jack under the transmission (red arrow).
Figure 12

Place a screw jack or hydraulic jack under the transmission (red arrow).

Working at the transmission cross member, remove the two 13mm transmission mount nuts (red arrows) and the six 13mm cross member mounting bolts (green arrows).
Figure 13

Working at the transmission cross member, remove the two 13mm transmission mount nuts (red arrows) and the six 13mm cross member mounting bolts (green arrows).

Working at the rear of the transmission, remove the four E12 bracket fasteners (red arrows).
Figure 14

Working at the rear of the transmission, remove the four E12 bracket fasteners (red arrows). Support the transmission bracket when removing the final fastener.

Remove the transmission bracket from the transmission.
Figure 15

Remove the transmission bracket from the transmission. Then remove the driveshaft flex-disc (red arrow). See our tech article on driveshaft flex-disc replacing. Once the flex-disc is removed, clean the transmission thoroughly.

Now you can remove the 30mm nut holding the driveshaft flange to the output shaft (red arrow).
Figure 16

Now you can remove the 30mm nut holding the driveshaft flange to the output shaft (red arrow).

I like to use a 3-jaw puller to remove the flange from the transmission.
Figure 17

I like to use a 3-jaw puller to remove the flange from the transmission. Install the puller and tighten it until the flange is free.

Then slide the flange off the transmission output shaft.
Figure 18

Then slide the flange off the transmission output shaft.

Now it is time to remove the seal.
Figure 19

Now it is time to remove the seal. I use a seal puller and slowly lever the seal out. You have to stick the puller into the seal and then lever it out. Now be careful not to damage the transmission housing and work gently and slowly (green arrow).

To install a new seal, slide it over the output shaft and press it in by hand.
Figure 20

To install a new seal, slide it over the output shaft and press it in by hand. Then slowly install the seal until it is flush with the transmission housing. You can tap it in using a rubber mallet. Be careful not to bend the seal or seal lip. Install the flange onto the output shaft. Then install the flange nut. Use Loctite 243 on the threads of the nut. Install the driveshaft to the transmission. See our tech article on driveshaft installing for more info. Reinstall the exhaust heat shields and exhaust.

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Page last updated: Sat 12/3/2016 02:44:03 AM