21 51 500 Removing and installing or replacing clutch release bearing/lever

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 535i, 2009 BMW 535xi, 2009 BMW 535i, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: (transmission removed)

New version (except M models)

Release bearing and release lever have been combined to form a single release module.

If possible, do not disassemble the release module. Otherwise there is a risk of the release module being incorrectly reassembled.

Installation:

Make sure that the correct cam (1) of the release bearing is on the sliding surface (2) of the release lever.

The positioning in relation to each other is identified by white dots on the cam (1) and the sliding surface (2).

NOTE: Do not grease sliding surfaces (2).

Fig 1: Identifying Correct Cam Of Release Bearing And Sliding Surface Of Release Lever

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Fig. A: Cam (1) of release bearing (A=12 mm) is on sliding surface of release lever.

This version is for 4-cylinder gasoline engines.

Fig. B: Cam (1) of release bearing (A=7 mm) is on sliding surface of release lever.

This version is for 6-cylinder gasoline and diesel engines.

Fig 2: Checking Release Bearing Dimension

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Remove release module (1) from spring wire clip.

Remove release module.

NOTE: Illustration similar.

Fig 3: Identifying Release Module

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Installation:

Check spring wire clip (5) and ball pin (6) for damage and replace if necessary.

NOTE: Illustration similar.

Fig 4: Identifying Spring Wire Clip And Ball Pin

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Previous version

Detach release bearing (1).

Installation:

Clean all sliding surfaces on clutch release bearing, check for damage and replace if necessary.

Do not grease clutch release bearing.

Sliding surfaces (2) of clutch release bearing must rest on sliding surfaces (3) of release lever.

Apply a thin coating of grease to sliding surfaces (2) of release bearing.

Grease , refer to BMW Service Operating Fluids.

Fig 5: Detaching Release Bearing

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NOTE: Illustration similar

IMPORTANT: On E60/E61 M5 and E63/E64 M6 only - apply a light coating of grease to guide sleeve.

Previous clutch release bearing:

Clutch release bearing with moving thrust plate (1).

Swivel motion of thrust plate (1) possible.

Fig 6: Identifying Swivel Motion Of Thrust Plate

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Withdraw release lever (4) from spring wire clip (5) and remove.

Installation:

Clean release lever.

NOTE: Illustration similar.

Fig 7: Identifying Release Lever From Spring Wire Clip

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Previous release lever

Installation:

Apply a thin coating of grease to release lever at sliding surfaces (1 and 2) only.

Grease , refer to BMW Service Operating Fluids.

Fig 8: Identifying Grease Applying Area

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Installation:

Check spring wire clip (5) and ball pin (6) for damage and replace if necessary.

Apply a thin coating of grease to ball pin (6).

Grease , refer to BMW Service Operating Fluids.

NOTE: The spring wire clip and ball pin must always be replaced on the S6S 420G transmission.
Illustration similar.

Fig 9: Identifying Spring Wire Clip And Ball Pin

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Clean guide sleeve (7).

Note on installation: (except for E60/E61 M5 and E63/E64 M6)

Do not grease guide sleeve.

If guide sleeve is greased, the release lever can stick on the guide sleeve.

NOTE: Illustration similar.

Fig 10: Identifying Guide Sleeve

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