Gears may not be selected, or changed. If SMG transmission is stuck in any gear, engine cannot be restarted.

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1 Page 1 of 6 SI B Manual Transmission February 2007 Technical Service This Service Information bulletin supersedes S.I. B dated December designates changes to this revision SUBJECT M5, M6 with SMG III; FC 4F42/4F43 - Hydraulic Unit Faults MODEL E60 M5 with GS7S47BG SMG transmission E63 M6 with GS7S47BG SMG transmission SITUATION SMG transmission goes into failsafe mode with Trans Light illuminated. Gears may not be selected, or changed. If SMG transmission is stuck in any gear, engine cannot be restarted. Any combination of the following fault codes may be stored in SMG control unit (listed by a frequency of occurrences): 4F42 Hydraulic unit, on period; 4F43 Hydraulic unit activation frequency, pressure build-up; 4F40 Hydraulic unit, pressure range undershot. In most cases, also the fault code 4FA0 (Clutch activation, position deviation) is stored together the SMG hydraulic system related faults. NOTE: If the fault code 4FA0 (usually with FC 4F80 "Transmission problem") is stored without any of the hydraulic system related faults, then refer to SI B for proper diagnosis. Also, refer to SI B for additional information regarding towing SMG equipped vehicles. CAUSE Intermittent failure in the SMG III hydraulic system. CORRECTION On a customer complaint basis only, interrogate SMG fault memory and execute the appropriate DIS/GT1 test modules in the following sequence: 1. Test Plan S2360_S3TFK - "Calculate accumulator pre-pressure charge". If the results are inconclusive, or if a fault code 4FA0 (Clutch activation) is stored in conjunction with FCs 4F42/ 4F43, then proceed to:

2 Page 2 of 6 2. Test Plan B2360_S3KUP -"Clutch". Work through all submenu selections from 1 to 5. If the results are inconclusive, then proceed to: 3. Test Plan B2360_S3HYE - "Hydraulic unit". From the test submenu select: "(4) Function check, pressure build-up". If the hydraulic pump fails to activate during the test, proceed to: 4. Test Plan B2360_S3HYR - "Hydraulic pump". From the test submenu select: "(4) Function check, hydraulic pump relay". Using MFK1 adaptor and 40-pin break-up box (PN /303) diagnose the SMG pump relay operation. Replace hydraulic pump relay (K6318) if found defective. 5. If during diagnosis, the SMG hydraulic system (or, a hydraulic pump) fails one of the executed test plans, then replace the complete SMG Hydraulic Unit (PN ) according to the procedure provided below. PROCEDURE 1. Prior to any work on SMG hydraulic system, the operating pressure must be reduced through the test plan "Replacement and repair S2360_S3SRV"; then selection (4) "Hydraulics"; then selection (3) "Before working on the hydraulic system pressure reduction" found in "Service Functions"/ "SMG transmission control". 2. Remove the SMG pump relay (K6318, black) located in the E-box. The K6318 relay should not be reinstalled until the repair procedure is completed. 3. Remove the SMG transmission from the vehicle. For the removal instruction refer to RA found in TIS. 4. Place and secure (e.g. with wooden blocks) the SMG transmission on the appropriate workbench. Make sure that the transmission fluid cooler/lines located at the bottom are not damaged. NOTE: The special SMG III transmission fixture tool shown on the illustration ( ) will be available in the near future to accommodate easier handling of the unit. 5. Unclip valve block wiring harness from the metal clips. 6. Remove one M8X35 Torx bolt (2) at the fluid reservoir. Note on reassembly Use new bolt (PN ), torque it to 22 Nm. 7. Remove two M8 self-locking hex nuts

3 Page 3 of 6 securing the clutch slave cylinder to the bell housing. Note on reassembly: Use new self-locking nuts provided (PN ). Torque them to 22 Nm. 8. Remove two M8X80 Allen head bolts (#1 on the pump housing), and two M8X25 Torx head bolts securing the hydraulic pump assembly (#1 on the pump/accumulator bracket). Note on reassembly: Clean the internal threads in the transmission housing to remove any residual locking material. Use new bolts provided: M8X80 - PN , M8X25 PN , Use Loctite 243 with two M8X25 bolts. Retorque all bolts to 22 Nm. 9. Remove 11 M8X25 Allen head bolts from the actuators block assembly. 10. Using an appropriate tool (e.g. plastic wedge), carefully pry-off the actuator block assembly from the transmission housing. Note: Make sure that the transmission housing sealing surface is not damaged/scratched during the removal process 11. Cover the transmission selector forks with a clean, lint-free cloth and remove residual sealing material from the sealing

4 Page 4 of 6 surface. 12. If one of the centering sleeves (1) remains in the removed actuator block, it should be removed and discarded. In such a case, install a new sleeve (PN ) in the transmission housing. 13. Align transmission actuator forks (1) in the central position, as shown on the illustration. 14. Apply a thin coat of Loctitereg; 573 (or Loctitereg; 518) on the mating surface (2). Note: Loctitereg; 573, or 518 can be purchased from your local Loctitereg; distributor. IMPORTANT: If Loctitereg; 573/518 is not available in your area, contact Technical Hotline/Drivetrain via Puma case (titled "SMG III Hydraulic Repair), and request a sample to be shipped to your attention. Availability of Loctite 573 from the BMW PDCs is expected shortly. 15. Carefully remove the replacement SMG Hydraulic Unit (PN ) from its original packaging and a protective foam. Make sure that all shifting pistons of the actuator block are centered, with the rounded areas of the shafts pointing upwards (as shown on the illustration). 16.With the help of another person, position the pump/reservoir/slave cylinder unit on the side of the transmission and at the same time gently place the actuator block on the transmission top opening. 17. Align the centering sleeves with the corresponding holes in the actuator

5 Page 5 of 6 block, and gently press on the block until it perfectly fits on the mating surface. 18. Secure the actuator block with 11 new M8X25 bolts (PN ), torque them to 22 Nm. 19. Secure the pump/reservoir and clutch slave cylinder with bolts and nuts provided. SMG Hydraulic Unit comes pre-filled with Pentosin CHF 11S fluid. Remove the rubber green transportation seal cap from the reservoir breather. Install the black rubber cap provided with the replacement kit. 20. Reinstall SMG transmission. 21. Connect vehicle to DIS/GT1. From the Service Functions select SMG Transmission, and Replacement and Repair S2360_S3SRV test module, then: Select: (4) Hydraulics, Select: (2) After replacing hydraulic unit with actuator block, Then perform 3 service functions, in the following sequence: 1. Teach-in clutch valve characteristic values 2. Adapt complete transmission 3. Teach-in clutch slip point. It is not required to perform bleeding procedure of the actuator block or clutch slave cylinder, since the hydraulic unit comes pre-filled. Re-insert K6318 hydraulic pump relay only when prompted by test module request. 22. If needed, top the hydraulic fluid level using Pentosin CHF 11S (PN ). PARTS INFORMATION Part Number Description Quantity SMG Hydraulic Unit 1

6 Page 6 of M8X25 Allen head bolt Centering sleeve (only if required) M8 self-locking nut M8X35 Torx bolt M8X25 Torx bolt M8X80 Allen head bolt 2 WARRANTY INFORMATION Covered under the terms of the BMW New Vehicle Limited Warranty. Defect Code Labor Operation: Labor Allowance: Refer to KSD Refer to KSD Refer to KSD Sublet 4 Toping hydraulic fluid with $4.00 Pentosin CHF 11S [ Copyright 2007 BMW of North America, LLC ]