E39 S6S 420G gearbox — BMW
E39 S6S 420G gearbox on BMW: 56 steps. What to remove, in what order, and what to check after.
Removing the six-speed S6S 420G manual gearbox from a BMW E39 540i. The available record is brief and lists the job as headings rather than full instructions, so treat it as a sequence check. The engine upper cover comes off, then the complete exhaust, the reversing light switch and speed sensor are disconnected, the propeller shaft is unbolted from the gearbox and its centre support released before it is removed. The engine is supported with the special tool and a wooden block, the cross member comes out, the engine and gearbox are lowered slightly to reach the gear-shift linkage, and the clutch hydraulics stay connected. Cleaning and greasing the input shaft splines is the main point on refit.
🧭 Before you start
Remove the engine upper cover and the complete exhaust, disconnect the reversing light switch and remove the speed sensor. Unbolt the propeller shaft from the gearbox, release the centre support and remove the shaft. Support the engine with the special tool on a wooden block, remove the cross member and lower the assembly slightly, then disconnect the gear-shift linkage and selector rod. Remove the gearbox bolts and the gearbox, leaving the hydraulic lines connected. Installation is the reverse, with clean, greased input shaft splines.
Fits: platform code 540I
Don't miss
- Support the engine on a wooden block with the special tool before removing the cross member.
- Do not disconnect the clutch hydraulic lines.
- Clean and lightly grease the input shaft splines before refitting.
- Bolt sizes M6, M8 and M10 have separate torque values; check each against the specification.
Written for this job from the workshop steps below · TorqFix editorial.
📋 Procedure
- Installation is in the reverse order of removal
- Remove the engine upper cover
- Remove the complete exhaust
- Clean the gearbox input shaft splines
- Apply grease to the gearbox input shaft splines
- Propeller shaft to gearbox:
- Disconnect the reversing light switch from the gearbox
- Remove the speed sensor
- Gearbox to engine:
- Remove the cross member
- Disconnect the propeller shaft from the gearbox
- Propeller shaft middle support
- Remove the propeller shaft
- Fit the special tool to support the engine
- Note: Use a wooden block to support the engine
- Lower the engine/gearbox slightly
- Disconnect the gear-shift control
- Loosen the securing clip
- Loosen the selector rod
- Note: Do not disconnect the hydraulic lines
- Remove the gearbox bolts
- Remove the gearbox
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.