21 21 500 Removing and installing/replacing clutch (SAC)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 528xi, 2010 BMW 528i, 2009 BMW 528xi, 2009 BMW 528i, and 2008 BMW 528xi. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

11 9 260
11 9 263
11 9 264
11 9 265 See ENGINE - SPECIAL TOOLS .
21 2 141
21 2 170
21 2 180
21 2 201
21 2 230
21 2 250 See MANUAL TRANSMISSION - SPECIAL TOOLS .

Necessary preliminary tasks:

Remove transmission . See 23 00 017 REMOVING AND INSTALLING TRANSMISSION .

Installation:

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

M54/M57/M57TU/N52/N52K/N53/S54 only:

Block flywheel with special tools 11 9 260 and 11 9 265 . See ENGINE - SPECIAL TOOLS .

Fig 1: Identifying Special Tool (11 9 260) And (11 9 265)

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N62 only:

Fig 2: Identifying Special Tools

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Block flywheel with special tools and 11 9 264 . See ENGINE - SPECIAL TOOLS .

Fig 3: Locating Flywheel Bolts

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Release screws and remove clutch from flywheel.

Installation:

Clean flywheel and check for wear and damage.

Replace damaged flywheel.

IMPORTANT: Always replace clutch plates fouled e.g. by oil, cleaning agent.

Observe the following procedure when installing the removed clutch and clutch plate.

Installation:

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

Insert special tool 21 2 180 in clutch.

Press special tool 21 2 180 together at handles (1) as far as it will go and tighten down knurled screws (2).

Adjustment ring of clutch is now secured in its original position (wear position).

Fig 4: Identifying Special Tool (21 2 180) And Knurled Screws

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NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings of pressure spring.

Fig 5: Identifying Locking Hooks Of Special Tool (21 2 180)

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Fit special tool 21 2 170 and tighten down at knurled screw (1).

Screw in spindle (2) until diaphragm spring (3) is tensioned on stop.

Fig 6: Identifying Special Tool (21 2 170) And Knurled Screw

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NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins.

Fig 7: Identifying Centre Clutch Plate With Special Tool

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Centre clutch plate (1) with special tool in dual-mass flywheel.

IMPORTANT: Install clutch plate in correct position.
Note designation for "engine side" / "transmission side".
Handle clutch plate with care. Do not touch surfaces of friction linings.

SPECIAL TOOL CHART

Special tool	Transmission
21 2201	GS6-37BZ
21 2 230	GS6-53DZ/BZ
21 2 141	S5D 390Z
21 2 250	GS6-17BG

Fig 8: Identifying Clutch And Dowel Pins

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Fit clutch (1) to flywheel. Tightening torque 21 2 1AZ . See CLUTCH - TIGHTENING TORQUES .

NOTE: Clutch (1) must be secured by way of dowel pins (2).

Fig 9: Removing Special Tools

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Release spindle (1) until load is fully removed from diaphragm spring. Remove special tools 21 2 170 and 21 2 180 . See MANUAL TRANSMISSION - SPECIAL TOOLS .

Fig 10: Identifying Special Tools And Screw

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Withdraw special tool from clutch plate with aid of accompanying screw (1).

Installing removed clutch with new clutch plate:

Installation:

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

IMPORTANT: Before installing a used clutch with a new clutch plate, always reset adjustment ring in new position.

Fig 11: Identifying Special Tool 21 2 180 And Clutch

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Set clutch down on a clean surface. Insert special tool 21 2 180 in clutch (1).

Fig 12: Identifying Locking Hooks Of Special Tool 21 2 180

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NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings in clutch.

Fig 13: Identifying Special Tool 21 2 170, Spindle And Diaphragm Spring

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Fit special tool 21 2 170 and tighten down at knurled screw (1).

NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins.

Screw in spindle (1) until adjustment ring of clutch (2) can be turned with special tool 21 2 180 at handles (3).

Press special tool 21 2 180 together at handles (3) as far as it will go and grip firmly.

At same time tighten down knurled screws (2).

Adjustment ring of clutch is now secured in new position.

Screw in spindle (1) until diaphragm spring is tensioned on stop.

Fig 14: Screwing In Spindle

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Centre clutch plate (1) with special tool.

IMPORTANT: Install clutch plate in correct position.
Note designation for "engine side" / "transmission side".
Handle clutch plate with care. Do not touch surfaces of friction linings.

Fig 15: Identifying Clutch Plate And Special Tool

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SPECIAL TOOL CHART

Special tool	Transmission
21 2 201	GS6-37BZ
21 2 230	GS6-53DZ/BZ
21 2 141	S5D 390Z
21 2 250	GS6-17BG

Fit clutch (1) to flywheel.

Tightening torque, 21 21 1AZ . See CLUTCH - TIGHTENING TORQUES .

IMPORTANT: Clutch (1) must be secured by way of dowel pins (2).

Fig 16: Identifying Clutch And Dowel Pins

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Release spindle (1) until load is fully removed from diaphragm spring (2)

Remove special tools 21 2 170 and 21 2 180 . See MANUAL TRANSMISSION - SPECIAL TOOLS .

Fig 17: Releasing Spindle

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Withdraw special tool from clutch plate with aid of accompanying screw (1).

Fig 18: Identifying Special Tools And Screw

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Installing new clutch

IMPORTANT: Locking piece may only be removed clutch is screwed down!

Installation:

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

Fig 19: Identifying Clutch Plate And Special Tools

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Centre clutch plate (1) with special tool.

IMPORTANT: Install clutch plate in correct position.
Note designation for "engine side" / "transmission side".
Handle clutch plate with care. Do not touch surfaces of friction linings.

SPECIAL TOOL CHART

Special tool	Transmission
21 2 201	GS6-37BZ;GS6-17BG
21 2 230	GS6-53DZ/BZ
21 2 141	S5D 390Z
21 2 250	GS6-17BG

Fig 20: Identifying Dowel Pins

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Fit clutch to flywheel. Tightening torque 21 21 1AZ . See CLUTCH - TIGHTENING TORQUES .

IMPORTANT: Clutch must be secured by way of dowel pins (1).

Carefully unscrew locking piece (1) clockwise or counterclockwise with a 14 mm WAF hexagon socket wrench (2).

Fig 21: Unscrewing Locking Piece

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NOTE: A slight snapping of the plate spring while unscrewing the lock is possible.

Fig 22: Identifying Special Tools And Screw

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Withdraw special tool from clutch plate with aid of accompanying screw (1).