Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 240998 Date: 011201
A/T - GM5 Clunk Noise
GROUP 24
Automatic Transmission
24 09 98
Woodcliff Lake, NJ
Service Engineering
December 2001
This Service Information bulletins supersedes S.I. 24 09 98 dated December 1998.
SUBJECT
E46 GM5 Transmission "Clunk" Noise
MODEL
E46 - 323iA, 328iA produced from 05/98 up to 03/00 with A5S360R (GM5) Transmission
SITUATION
A "Clunk Noise" is heard/felt during situations of load reversal. The situation can occur during downshifts, release of accelerator pedal at 20-30 mph
with 2000-2500 rpm or in reverse at 3000 rpm and accelerator pedal released.
This concern involves E46 vehicles with M52TU engines, fitted with transmission A5S360R until transmission serial number 162728.
CAUSE
Excessive axial clearance between transmission output shaft and transmission output flange.
CORRECTION
A production change has been implemented as of transmission serial number 162728.
In the event of a customer complaint on vehicles with a transmission serial number less than 162728 the location of the noise should be determined
during a test drive as follows:
-- With the engine warm, drive the car at a speed between 20 and 25 MPH. While traveling in this speed range, quickly release the accelerator
pedal (causing engine braking to occur).
-- If a muffled knocking noise is heard coming from the rear-axle area after going into decel mode, or shortly thereafter, then the cause is with the
transmission output flange.
Replace transmission output flange with the new version P/N 24 21 7 515 388 with spring washer as per repair instructions 24 21... (available as
of TIS CD 9/98).
-- If the noise does not appear to be coming from the rear axle area further diagnosis is required in order to isolate the source of the "clunk".
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Recommendation would be to utilize a chassis ear to locate the source of the clunk noise.
The repair kit "Output flange with spring washer" (PN 24 21 7 515 388) can be ordered through the regular parts channels.
PROCEDURE
Installation of the kit on the transmission:
1. Remove the exhaust pipe from the vehicle as per procedure 18 00 020 "Removing and Installing complete exhaust system M52 TU".
2. Remove the propeller shaft from the transmission as per procedure 26 11 000 "Removing and Installing complete propeller shaft"
3. Hold output flange (1) with special tool 23 0 020. Remove hexagon nut. Remove output flange (1). On the transmissions from serial number
7912, remove the retainer (snap ring) from the output shaft Discard the nut, the seal 0-ring of the flange, and the retainer.
4. Prepare the retrofit kit:
5. Install new drive flange 0-ring (1) (from the kit) into the new drive flange (2) using Transmission fluid or petroleum jelly
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6. Install the "Retainer" (1) included in the kit using snap ring wrench, as deep as possible on the output shaft (2).
Note:
Be careful to not damage lip seal when installing the "Retainer".
7. Install new drive flange with 0-ring onto the transmission output shaft and push the retainer fully into place
8. Install the spring washer (1) from the kit as shown on the drive flange (2) (big diameter face to flange 2, small diameter face to nut).
9. Apply coat of "LOCTITE 242" to the thread of the output shaft.
NOTE:
"LOCTITE 242" is the only thread locker/sealant approved for this repair, and it is available from your local Loctite distributor.
10. Tighten the new nut (1) (included gun the kit) on the output shaft using a Hexagonal M30 Socket
11. Tightening torque: 80 Nm
PARTS INFORMATION
Part Number Description Quantity
24 21 7 515 388 Repair set output flange 1
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
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Defect Code 24 21 90 31 00
Labor Operation: 24 211 00
Labor Allowance: 17 FRU
