21 21 500 Removing and installing/replacing clutch (SAC 240)

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.

Special tools required:

Necessary preliminary tasks:

Remove transmission . See REMOVING AND INSTALLING TRANSMISSION (GS6-53DZ) N54

M57T2

Block flywheel with special tools 11 9 260 and 11 9 265 .

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

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N54

Block flywheel with special tools 11 9 260 and 11 9 265 .

Fig 2: Identifying Special Tools (11 9 260) And (11 9 265)

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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.

Fig 3: Locating Flywheel Screws

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

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 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: Locking Hooks Of Special Tool

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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 Knurled Screws, Spindle And Diaphragm Spring

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

Centre clutch plate (1) with special tool 21 2 270.

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 7: Identifying Centre Clutch Plate

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Fit clutch (1) to flywheel.

Tightening torque 21 21 1AZ .

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

Fig 8: 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 .

Fig 9: Identifying Spindle And Diaphragm Spring

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

Fig 10: Identifying Clutch Plate With Screw

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Installing removed clutch with new clutch plate:

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

Set clutch down on a clean surface.

Insert special tool 21 2 180 in clutch (1).

Fig 11: Identifying Clutch

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

Fig 12: 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).

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

Fig 13: Identifying Knurled Screw

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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 Spindle And Ring Of Clutch

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Centre clutch plate (1) with special tool 21 2 270.

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 Centre Clutch Plate With Special Tool (21 2 270)

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Fit clutch (1) to flywheel.

Tightening torque 21 21 1AZ .

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 .

Fig 17: Identifying Spindle And Diaphragm Spring

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

Fig 18: Identifying Accompanying Screw

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Installing new clutch

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

Centre clutch plate (1) with special tool 21 2 270.

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 19: Identifying Centre Clutch Plate With Special Tool (21 2 270)

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Fit clutch to flywheel.

Tightening torque 21 21 1AZ .

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

Fig 20: Identifying Clutch With Dowel Pins

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

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

Fig 21: Unscrewing Locking Piece

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

Fig 22: Identifying Accompanying Screw

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