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2002 BMW M5 E39 Dinan
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Discussion Starter #1 (Edited)
My rear main seal was leaking, so it was time to replace it. Car had been sitting for a while, due to various reasons.
But on a cold and drizzly December night at 10:30PM we commenced the work.

I almost did not have any proper tools (had been using friend's tool-sets in past), so this took couple days to complete until I chased down all the specific tools.

This is not a full DIY, but I did my best to take as many pics as possible and video to illustrate.
The pics fall short of showing bolt-by-bolt instructions, but its the best I could do while still managing to work on the car. Some day when someone's doing this at a shop I'll be a dedicated photographer.

I also made a video, figured that would help a little for people to visualize the work.
The man mostly seen below is my friend-- Didzis from Latvia.

Note: The main seal was replaced while I was in process of removing the matte-black vinyl, since the intention is to paint it matte black in near future.

The Video:
<object height="587" width="1000">

<embed src="http://www.youtube-nocookie.com/v/qIf5nbjFFJI?fs=1&hl=en_US&rel=0&hd=1" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" height="587" width="1000"></object>




The Pics:



Getting ready to work on the car




Closeup of the glove






The front end of the car jacked up by the subframe, so you can simultaneously slide 2 jacks under the front of the car.




Posing before the work begins




Found my instructions manual for the E39 BMW M5. Easy directions.




Close-up of manual.




Ultra-Close-up of manual.




Exhaust removed






The guibo bolts were impossible do get loose, so the Gubio ended being cut apart. Original Guibo was ripped as well, so a new one was going in for replacement anyway.






The guibo cut off.



 

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2002 BMW M5 E39 Dinan
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Discussion Starter #2 (Edited)

Guibo V.S. Humans ... humans win!




Closeup of cut off Guibo




The mess under the car






Transmission-to-engine bolts removed




Transmission-to-engine bolts in consecutive order




Engine is supported by jack-stands, so the engine would not end up resting on the steering linkage when the transmission is removed.




To remove the transmission, the jack was used. The center of gravity is on the oil pan bolt. The transmission weights in at about 110 pounds / 50kg.




Here you see the transmission mounts being removed.


 

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2002 BMW M5 E39 Dinan
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Discussion Starter #3 (Edited)

The crack between engine and transmission is showing once the transmission mounts and engine-to-transmission bolts are removed.




The transmission removed, clutch pressure plate is showing in darkness.




Getrag 6-speed transmission for BMW E39 has landed!




Another view of the Getrag 6-speed.




Here the core of the Flux Capacitor revealed.

Check out the glowing pins in center of Flux Capacitor due to the extreme heat produced of the burst of up to 1.21 Gigawatts of power when the drive is engaged through the Getrag 6-speed transmission to the rear wheels.

Normally glowing occurs only above 88 miles per hour.

Note also that this is exactly the same thing that Hans Solo & R2D2 has to fix on the Millennium Falcon when their warp-drive fails.

(This is the clutch pressure plate if you don't speak in BTF or R2D2 languages)




The close-up of dual mass flywheel with the metal gears for the starter motor.




Above the flywheel




The clutch after 75,000 miles of my driving. Going in for another 75,000 miles... actually until the rear main seal has to be replaced again.




Close-up of the clutch (disc).




BMW special hex tool utilized to remove the flywheel.


 

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Discussion Starter #4 (Edited)

Clutch and flywheel sitting on the ground.





The rear main seal and surrounding areas, quite dirty.





The rear main seal and surrounding areas, now a little cleaner.





The transmission on the floor, with the Guibo still attached.









Cleaning up the mess from the salt-flats





Rear main seal removed.





Close-up of rear main seal area. Note the oil happened to be PERFECTLY level with the top of the oil pan. This was by chance, but the oil was extra high up since the car has the front tilted upward with the front wheels in the air.
You can see the reflection of the crank-shaft in the oil.






Close-up of the internals.
 

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2002 BMW M5 E39 Dinan
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Discussion Starter #5 (Edited)

Putting on the gasket for the rear main seal. The bottom has no gasket since the oil pan steel gasket isolates it there. Just make sure to put some oil on the finger and coat the oil pan gasket lightly so it's not dry when installing new rear main seal.




The underside bolts of rear main seal are being screwed in.




We are done with what we came for, its down-hill from here. '




Cleaning up the flywheel before install






Appropriate torque is being used to tighten the flywheel. The torque specs can be found on Vantaam5's DIY: http://www.m5board.com/vbulletin/e39-m5-e52-z8-discussion/150054-clutch-change-diy-pics.html




BMW special tools to tighten the self adjusting clutch (springs).
Since I have no vocab available for these tools I will call the circular tool "Spring-tool" and the clamp-type looking one "Pressure-tool".




BMW special tools along w/ the clutch pressure plate and clutch disc.




The differential shown here, obviously leaking. This is next project, since we didn't have time for the diff while fixing rear main seal.


 

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Discussion Starter #6 (Edited)

Shown is a close-up of BMW/Dinan self adjusting clutch and clutch pressure plate.
Note the 3 springs on the pressure plate. If these springs are not re-tightened during re-install of a used clutch, chances are the clutch will slip once driven. The tools illustrated above will be used for this purpose. To my best knowledge this is also ought to be done on a new clutch to prevent any chance of slipping.

Also note that the clutch-centering tool is not inserted as it ought to be. We removed it so we could get more pics, and forgot to put it in, when taking the 2nd set of pics. (Yes we installed and removed the pressure plate 3x so we could get proper pics).





The clutch pressure plate with the spring-tool attached.
For further explanation watch the video.




Here is the pressure plate and clutch being engaged by the pressure-tool.




Another angle




Note the springs, they are now tightened.




Checking the oil in the transmission. The proper oil level is so the oil level is flush with the hole shown above when the transmission is sitting on a level surface.



 

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Discussion Starter #7 (Edited)

Pic: Swinging by TruSpeed Motorcars in Newport Beach and BMW dealer and to pick up more parts, screws and bolts. Best of my knowledge is to get replace all the bolts and screws that you removed, including the throw out bearing (clutch release bearing). So did I at least. When the M5 needs attention; unless I'm under my M5 in my driveway, it is on one of these lifts.




Tired, tired, tired.












At the stealership whie picking up parts:
I have no idea which M5 that sign is referring to. Maybe the one driven by the unicorn or the flying pink elephant.



 

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Discussion Starter #8 (Edited)

Re-installing the transmission




15-min full-on wrestling match.




Life-time BMW fluid sign visible. Clearly not obey by me.




World Wresting Championship in Transmission vs. Humans : Finally the humans win.




Re-install of new guibo.




Heating the exhaust bolt to get it out. Heating did not help. Hammer did not help.




Cut it off with a Dremel and then destroyed 4 metal drill bits to drill it out. Real SOB this one.




Exhaust about to go back in.




5:10 AM. The car is almost ready, worked throughout the night.




Fuel stop




Re-setting all Check Engine Light / Service Engine Soon / SES codes that popped up during repairs and running car with no exhaust or oxygen sensors.




Run to the top of the mountain at sunrise, to test if clutch is slipping. No slip in the clutch after it was warmed up @ WOT in 2nd, 3rd, 4th and 5th.
Job well done.



 

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Nice write up with pictures! The pictures are really clear! Good job on DIY!
 

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Thanks a million for taking care of making pictures of the whole process Terabass! Makes it for one very entertaining read, thanks for sharing!

Will be doing my clutch + flywheel + RMS around March. While Frits takes care of that replacement, I will have fun with cleaning up the transmission and other assorted parts :)
 

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Your photos are phenomenal! I really appreciate it when people take the time to document these kind of processes; it's not done near as much as it should!

Great work! :thumbsup:
 

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I LOVE your pic,man!!!!!!!!!!!:goldcup:

Thanks for the write up,seems you guys had some fun!

Still can not get over the latvian repair manual and explanation how the diff workshihahihahiha

Keep up the good work!
 
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