Subject Page

E85 Transmissions.................................................................................3
Transm ission C odes................................................................................3
GS6-37BZ Manual Transmission..........................................................6
6 Speed Pow er Flow .............................................................................10
W orkshop H ints.....................................................................................14
Sequential Manual Gearbox (SMG) 6-Speed.....................................15
System C om ponents.............................................................................16
W orkshop H ints....................................................................................21
Review Questions................................................................................24
Table of Contents
E85 Transmissions
2
E85 Transm issions
E85 Transmissions
Model: E85
Production: Start of Production MY 2003
Objectives:
After com pletion of this m odule you w ill be able to:
Identify the four different transm issions available for the E85.
Explain w hy is extrem ely im portant to properly torque the 6 speed m anual transm ission
m ounting bolts to the engine block.
D escribe the changes to the transm ission input shaft.
List the system s influenced by the Sportbutton.
Explain w here SM G system faults can be visually identified.
U nderstand w hy Teaching G earboxm ust be perform ed w ith the D ISplus/G T1.
3
E85 Transm issions
E85 Transmissions
There are 4 different tranm issions offered for the E85:
2 m anual transm issions:
G S5-20B G 5-speed m anual transm ission (know n from the E46 as S5D -250G ). The brief
designation is the B -gearbox.
G S6-37B Z 6-speed m anual transm ission. The brief designation is the H -gearbox.
Autom atic transm ission:
G A5H P19Z autom atic transm ission is available as an option (code 205). This transm is-
sion is know n from the E46 as the A5S-325Z.
Sequential M anual G earbox:
The Sequential M anual G earbox (SM G ) is available as an option (code 206). The basis of
the SM G is the H -gearbox (know n as H -SM G ).
The follow ing table show s the engine/transm ission com binations:
Dynamic Driving Control (if equipped)
For sportydriving, the optional D ynam ic D riving C ontrol function is activated by pushing
the Sportbutton on the center console next to the gearshift lever. W hen this function is
activated, the follow ing control m odules are also influenced:
H -SM G C ontrol M odule - shorter gearshift tim es
EG S C ontrol M odule - Sport shift m ode.
Note: Shifting the Autom atic Transm ission G ear Shift Lever to the left from D into the M S
position activates the Steptronic Transm ission Sport Program .
Engine Manual SMG
(optional)
Automatic
(optional)
M 54B 30 G S6-37B Z H -SM G
G A5H P19Z
(A5S-325Z)
M 54B 25
G S5-20B G
(S5D -250G )
H -SM G
G A5H P19Z
(A5S-325Z)
4
E85 Transm issions
Exam ple - autom atic transm ission:
G A 5 H P 19 Z
M anufacturer:
G = G etrag
J = Jatco
R = R M PT
Z = ZF
M anufacturer's serial num ber
H P = H ydraulic planetary gear
R = R ear w heel drive
T = Transm ission
Alternatively: gearbox type/size/
torque (N m )
N um ber of gears 1 to 9
C = C ontinuously
A = Autom atic gearbox
F = R esearch gearbox
R = R eduction gearbox
Y = H ydrostatic gearbox
G earbox
5
E85 Transm issions
Exam ple - m anual transm ission:
G S 6 - 37 B Z
M anufacturer:
G = G etrag
J = Jatco
R = R M PT
Z = ZF
B = Petrol gear ratio
D = D iesel gear ratio
G earbox type:
37 = "H "
39 = "F"
53 = "G "
20 = "B "
M anual gearboxes:
- = Standard w ith m anual gearshift
S = SM G
X = All-w heel drive w ith m anual gearshift
W = All-w heel drive w ith SM G
N um ber of gears 1 to 9
C = C ontinuously
S = M anual gearbox
F = R esearch gearbox
R = R eduction gearbox
Y = H ydrostatic gearbox
G earbox
6
E85 Transm issions
E85 GS6-37BZ Manual Transmission (if equipped)
The G S6-37B Z 6-speed m anual transm ission (H -gearbox) is used in the E85 w ith the
M 54B 30 engine. The gearbox is designed by Zahnradfabrik Friedrichshafen (ZF) and built
and supplied by ZF and G etrag. This is w hy the gearbox designation bears the endings of
both "Z" and "G ." The changes to the G S6-37B Z com pared w ith m anual transm issions cur-
rently used in B M W s are:
Flanged dam ping block
Alum inium bolts (connecting to engine block)
Alum inium bolt (connecting case halves)
Input shaft m ounting in dual-m ass flyw heel
Involute input shaft teeth
Shift gate for guiding the selector shaft
External shift w ithout play in neutral position
N ew dual-m ass flyw heel
Components
The transm ission consists of the follow ing:
Transm ission case (front and rear half)
Transm ission shafts
G ear sets
G ear synchronizers
Shift m echanism
1. Selector sleeve, 5th/6th gear 6. Reverse gear 11. 6th gear
2. Selector sleeve, 3rd/4th gear 7. 1st gear 12. 5th gear (direct 1:1)
3. Selector sleeve, 1st/2nd gear 8. 2nd gear 13. Countershaft
4. Selector sleeve, reverse gear 9. 4th gear 14. Input shaft
5. Output shaft 10. 3rd gear
and the engine-side com ponents:
D ual-m ass flyw heel (ZM S)
C lutch
7
E85 Transm issions
Transmission Case
The casing is m anufactured from diecast alu-
m inium and flanged m ounted w ith alum inium
bolts to the engine block (arrow s).
The front half of the casing is also bolted to the
rear half w ith alum inium bolts. The casing is
secured at the rear w ith 4 bolts to the dam ping
block.
Note: Refer to TIS for correct tightening torque! For
additional and updated information, refer to the Repair
Instructions.
The bolted dam ping block (1) increases the transm is-
sion application for different vehicles. M odifying the
acoustic dam ping to different vehicle types is achieved
by changing the dam ping block.
Dual-mass Flywheel (ZMS)
A specially developed dual-m ass flyw heel is used
w ith the H -gearbox. B ecause the 6-speed m anual
transm ission has m ore gears, the flyw heel is m od-
ified to com pensate for vibration and noise.
In this flyw heel, the 2 m asses are connected via
inner and outer dam pers (rubber like dam ping
m aterial).
The m asses are now supported by a plain bearing
(no longer in a ball bearing). The plain bearing
requires less space and enables an additional inner
dam per to be used.
The transm ission input shaft is supported through the flyw heel in a
needle bushing w ith a roller pilot bearing. The flyw heel is connect-
ed to the crankshaft flange w ith Torx socket bolts.
Clutch: 03/2003 w ill introduce new heavy m etal-free friction linings
w hich satisfy the requirem ents of used car regulations.
8
E85 Transm issions
Input Shaft
The input shaft is approx. 25 m m shorter than
that in the 5-speed. The input shaft longitudinal
splines have an involute shape.
Involute Toothing: This denotes the special
shape (m athem atical curve) of the toothed seg-
m ents of the input shaft splines (22 teeth total).
This creates linear contact (dots show n to the
right) w ith the toothed segm ents to the clutch
drive plate center splines. The reduced friction
of the linear contact provides easier declutching
operation.
The splined clutch drive plate hub and guide sleeve form a seal to decrease contam ination
of the input shaft. The involute shaped splines m ake it easier to rem ove and install the trans-
m ission.
Transmission Shift Mechanism
The short shifttravel of the E85 gearshift handle required a m odification to the selector
forces of the internal gearshift m echanism . This changed the internal shift gate and shift-
gate finger. The shift gate finger is perm anently attached to the selector shaft and engages
the shift gate. The shift gate and finger precisely guide the selector shaft, conveying a pre-
cise gearshift sensation to the driver. This also provides a passive lockw hich prevents 2
gears from being sim ultaneously engaged.
1. Shift finger, 5/6 gear
2. Shift finger, 3/4 gear
3. Passive lock
4. Shift finger, 1/2 gear
5. Shift gate finger
6. Shift gate
7. Shift finger, reverse gear
9
E85 Transm issions
The gears are shifted by selector forks. The design dictates that the selector fork for 1st
and 2nd gears is transm itted as follow s: W hen the selector shaft is pushed forw ards
(engagem ent of 1st gear), the selector fork forced is m ultiplied as it m oves backw ards to
engage 1st gear.
The cham feredshift gate precisely guides
diagonal gearshifts (2nd to 3rd, 4th to 5th and
vice-versa).
1. Selector sleeve, 1/2 gear
2. Shift gate
3. Shift gate finger
A further function of the shift gate and the shift gate finger is to absorb "m isuse forces" cre-
ated by the driver at the gearshift lever (previously transm itted via the selector shaft to the
selector forks). A reduction of selector forces is achieved by low pretension springs at the
5/6 gutter, reverse gear and 1/2 gutter (helical coiled spring).
1. Spring, 5/6 gutter
2. Helical coiled spring, 1/2 gutter
3. Shift finger, 5/6 gear
4. Spring, reverse gear
Note: A correctly operating selector force m ech-
anism ensures that the gearshift lever is w ithout
play in neutral.
Notes:
10
E85 Transm issions
Transmission Gear Sets
The G S6-37B Z is designed for 5th gear to be direct and 6th gear as an overdrive.
Gear Synchronizers
A triple-taper synchronizer is installed for 1st and 2nd gears. A double-taper synchronizer
unit is installed for 3rd and 4th gears. A single-taper synchronizer unit is installed for 5th,
6th and reverse gear.
6-Speed Transmission Power Flow
The individual gear pow er flow s for the M 54B 30 engine are illustrated in the next few pages.
The pow er flow s illustrated are applicable to an input torque of 300 N m at a speed of 3500
rpm . The step-up ratio from the input shaft to the countershaft is 1.38. The input torque at
the countershaft is 390 N m .
Power flow in 1st gear
An input torque of 300 N m produces an output torque of 1226 N m .
Gear Ratios
1 2 3 4 5 6 R
4.350 2.496 1.665 1.234 1:1 0.851 3.926
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E85 Transm issions
Power flow in 2nd gear
An input torque of 300 N m produces an output torque of 704 N m .
Power flow in 3rd gear
An input torque of 300 N m produces an output torque of 470 N m .
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E85 Transm issions
Power flow in 4th gear
An input torque of 300 N m produces an output torque of 347 N m .
Power flow in 5th gear
The transm ission output torque is equal to the input torque (1:1 direct).
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E85 Transm issions
Power flow in 6th gear
An input torque of 300 N m produces an output torque of 240 N m (overdrive).
Power flow in reverse gear
An input torque of 300 N m produces an output torque of 1107 N m (reverse rotation).
14
E85 Transm issions
Workshop Hints
Removing Transmission
The case is flanged m ounted w ith alum inium bolts to the engine block (arrow s). The front
half of the case is also bolted to the rear half w ith alum inium bolts. These aluminium bolts
may only be used 3 times.
Note: Refer to TIS for correct tightening torque!
For additional and updated information, refer to
the Repair Instructions.
The shortened input shaft w ith the involute teeth
m ake it easier to rem ove and install the trans-
m ission.
Installing Transmission
A special lubrication procedure is required for the
involute teeth on the input shaft. Lubrication is
carried out w ith tw o special tools:
C arefully slide the grease scraper sleeve
(P/N 21 2 220) over the input shaft up to the
guide tube. This rem oves any previous lubri-
cation and debris.
C arefully slide the grease application sleeve
(P/N 21 2 221) over the input shaft up to the
guide tube.
U sing a brush, spread the grease evenly on
the teeth and the profile base up to the grease
application sleeve.
C arefully pull back the grease application
sleeve over the shaft. This provides an equal
distribution over the entire spline contact sur-
faces.
15
E85 Transm issions
E85 SMG 6-Speed Sequential Manual Gearbox (if equipped)
The optional Sequential M anual G earbox (H -SM G ) is a further developm ent of the E85
G S6-37B Z 6-speed m anual (H -gearbox). C om pared to previous SM G technology,
changes include:
C om pletely new transm ission
M ounting positions of the hydraulic com ponents and the sensors on the transm ission
housing.
In com bination w ith the SM G option, the custom er also obtains the D ynam ic D riving
C ontrol function. This function provides a Sporteffect on driving by influencing the Engine
M anagem ent, Transm ission (SM G and EG S) and Electronic Pow er Steering (EPS) control
system s. This function is activated w ith the Sportbutton.
System Overview
- Inputs/Outputs
1. Power distribution box
2. Instrument cluster
3. Gearshift lever
4. Illuminated shift gate
5. EWS III
6. MS45 ECM
7. Dynamic Driving Control
Sport button
8. SMG assembly on transmission
Hydraulic unit
Shift travel sensor
Selection angle sensor
Input speed sensor
Clutch control travel sensor
9. Reverse light relay
10. Starter motor
11. PT-CAN
12. Diagnosis Bus- DISplus/GT1
13. SMG steering wheel with
shift paddles
14. General Module - GM5
15. Brake light switch
16. SMG Control Module
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E85 Transm issions
System Components
The H -SM G system is m ade up of the follow ing com ponents:
SM G gearshift lever
SM G steering w heel w ith shift paddles
Sportbutton (D ynam ic D riving C ontrol)
SM G hydraulic system
SM G C ontrol M odule
R everse light relay
Transm ission
D isplays/indications in Instrum ent C luster
SMG Gearshift Lever
The design of the lever and the shift gate is sim ilar to the previously used SM G shift lever.
The shift gate depicted on the gearshift knob features the D sym bol instead of the C
sym bol for cruise m ode. The lever is connected to the transm ission by electric leads only
and the gearshift lever positions are m onitored by 7 H all sensors.
Operation
A dow nshift is perform ed w hen the lever is pressed forw ard.
An upshift is perform ed w hen the lever is pulled backw ard.
The gearshift lever position display (indicated w ith LED s) is integrated in the gearshift lever
center console trim , behind the gearshift lever.
SMG Steering Wheel with Shift Paddles
A gear change can also be perform ed using the
shift paddles on the steering w heel.
Operation
An upshift is perform ed w hen either shift pad-
dle is pulled backw ard
A dow nshift is perform ed w hen either shift
paddle is pressed forw ard.
17
E85 Transm issions
Sport Button
Pressing the Sportbutton (1) activates the
D ynam ic D riving C ontrol function and selects
sportier transm ission perform ance (shorter
gearshift tim es). This function can also be
selected in cruise m ode.
The request signal is m onitored by the M S45
EC M w hich transm its the signal to the SM G and
EPS C ontrol M odules.
If there are no faults in the C ontrol M odules, the
EPS C ontrol M odule illum inates the function
light in the Sport button.
SMG Hydraulic System
The clutching operation and the gear shift is perform ed autom atically by the SM G hydraulic
system . The H -SM G hydraulic system has sim ilar com ponents and functions as the previ-
ous SM G hydraulic system .
Installation location
In com parison w ith the previous SM G , the m ounting positions of the hydraulic system com -
ponents in the H -SM G have undergone significant changes, as can be seen in the follow -
ing 5 illustrations:
1. Shift/selector actuator
2. Pressure accumulator
3. Connections for:
Shift travel sensor
Selection angle sensor
4. Clutch control travel sensor
5. Clutch actuator
Left Side View
18
E85 Transm issions
1. Hydraulic pump
2. Transmission input speed sensor
3. Expansion tank
4. Valve block
5. Shift/selection actuator
1. Selection angle sensor 6. Pressure accumulator
2. Shift travel sensor 7. Selector shaft connection
3. Shift/selection actuator mounting hole
4. Expansion tank 8. Clutch actuator with
5. Valve block control travel sensor
1. Shift/selection actuator 4. Hydraulic pump
2. Valve block 5. Pressure accumulator
3. Expansion tank 6. Valve block guard
Right Side View
Top Rear View Bottom Rear View
19
E85 Transm issions
1. Shift/selection actuator
2. Expansion tank
3. Valve block
4. Hydraulic pump
5. Pressure accumulator
6. Clutch actuator with clutch control
travel sensor
C om pared w ith the previous SM G hydraulic system , the H -SM G hydraulic system is slight-
ly m odified in the follow ing areas:
The electrom echanical reverse light sw itch has been om itted.
The valve block is located underneath the transm ission.
The expansion tank is located on the right side of the transm ission w ith new m in/m ax fill
level m arkings.
The electrohydraulic pum p is located on the right side of the transm ission.
O n the left side of the transm ission, below the clutch actuator, is a central connector for
the valve block (solenoid valves EV0 to EV3, pressure sensor, voltage and ground sup-
ply to the valves).
Flexible high pressure hydraulic lines w ith quick-connect couplings are used.
Rear View
20
E85 Transm issions
1. Shift/selection actuator
2. Shift travel sensor
3. Selection angle sensor
4. Pressure accumulator
5. Clutch actuator with clutch control travel sensor
6. Hydraulic pump
7. Transmission input speed sensor
8. Expansion tank
9. Valve block
SMG Control Module
The SM G C ontrol M odule is located in the electronics box at the front left in the engine
com partm ent. It is positioned next to the EC M , in place of the EG S C ontrol M odule.
1. Engine Control Module (ECM)
2. SMG Control Module
3. ECM (main) relay
4. Fuel injector relay
5. SMG hydraulic pump relay
21
E85 Transm issions
Displays/Indications
The selected drive positions are displayed in 2 segm ents in the instrum ent cluster. The
selected gear position (1-6) is displayed in the right segm ent (2).
The drive m ode is displayed in the left segm ent (1), "D " for autom atic m ode. N o sym bol
appears in the left segm ent w hen the m anual drive program is selected. O nly the selected
gears are displayed in the right segm ent.
A fault can also be displayed in the left segm ent w ith "F." A serious gearbox
fault is indicated by an indicator light in the instrum ent cluster.
Workshop Hints
Central Connector
To sim plify access, a sm all central connector is located on the left side of the gearbox below
the clutch sensor. The central connector incorporates the circuit connections for the fol-
low ing hydraulic unit com ponents:
W iring for hydraulic valves
Signal line for pressure sensor
Voltage and ground supply for pressure sensor
G round connection for hydraulic valves
The gearshift lever accom m odates a M icro-Q uadlock system w ith a 12 pin pin tray. Tw o
pins are additionally assigned in the U S version. They are the outputs for the illum inated
gearshiftlever position indicator, w hich is located on the driver's side next to the gearshift
lever on the center console.
22
E85 Transm issions
SMG Bus System Overview
Diagnosis
D iagnosis corresponds to E46 diagnostics and contains the follow ing:
R ead identification
R ead fault m em ory
D elete fault m em ory
D iagnosis request
Programming
The SM G C ontrol M odule is program m able. Program m ing m ust be perform ed w henever
the SM G C ontrol M odule has been replaced.
Notes:
23
E85 Transm issions
Working on Hydraulic System
Note: Prior to any work on the hydraulic system, the system pressure must be reduced with
the service function "Before working on hydraulic system" in the DISplus/GT1.
The hydraulic pum p relay m ust be rem oved to prevent the hydraulic pum p from activat-
ing. The relay m ust not be reconnected for the entire duration of the repair w ork.
The service function "After w orking on hydraulic system " m ust be im plem ented w ith the
D ISplus/G T1 (to vent the hydraulic system ).
The service function "Teach gearbox" m ust be im plem ented w ith the D ISplus/G T1. The
hydraulic pum p m ust not run w hen dry!
After w ork is com pleted on the hydraulic system , the hydraulic fluid level m ust be
checked and topped up if necessary. The hydraulic pum p relay can be reinstalled. The
hydraulic fluid level m ust be checked again.
Teaching Gearbox
The service function "Teaching gearbox" m ust be im plem ented w ith the D ISplus/G T1 w hen
the follow ing com ponents are replaced:
SM G C ontrol M odule
SM G Transm ission
C lutch
C lutch sensor
Note: The SM G control system learns the clutching characteristic during the drive off oper-
ation. There m ay be im paired com fort during the initial gearshift operations.
24
E85 Transm issions
Review Questions
1. List the four different transm issions available for the E85.
2. W hy is extrem ely im portant to properly torque the 6 speed m anual transm ission m ount-
ing bolts to the engine block?
3. W hat does the term Involute Toothingrefer to?
4. The Sportbutton can influence w hat three system s in an E85?
5. W here can SM G system faults be visually identified by the driver?
6. W hat procedure m ust be perform ed after replacing any of the follow ing com ponents:
SM G C ontrol M odule, SM G transm ission, clutch, clutch sensor?