21 90... Troubleshooting the clutch

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.

TROUBLESHOOTING CHART

Fault	Cause	Remedy
Clutch slipping	a) Clutch pressure too low.	a) Replace clutch Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	b) Lining too heavily worn.	b) Replace clutch plate Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	c) Lining oiled- Leaks: Engine Crankshaft radial seal at front and rear incl. end cover, oil sump, cylinder head gasket, cylinder head, oil filler cap, timing case cover, flywheel mounting bolts Cooling system Hoses and connections, heating valves, sealing plugs on engine block Steering unit Steering gear, servo pump, hydraulic lines and connections Transmission Drive shaft radial seal, sealing plugs of countershaft Release bearing	c) Carefully rectify leaks, clean oil contamination and replace clutch plate Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	d) Clutch was overheated.	d) Replace clutch Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	e) Clutch is not an original equipment BMW part.	e) Install original-equipment BMW part.
Clutch stick/slip	a) Lining not acc. to specification.	a) Replace clutch plate Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	b) Lining oiled: Causes: refer to "clutch slipping, point c"	b) Replace clutch plate Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	c) Release unit presses on one side.	c) Check release lever.
	d) Clutch presses at an angle.	d) Replace clutch Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	e) Crankshaft does not align with transmission input shaft.	e) Check engine/transmission contact face, adapter sleeves and cover plate for damage.
	f) Engine and transmission suspension defective.	f) Replace engine and transmission suspension.
	g) Clutch plate not an original equipment BMW part.	g) Install original-equipment BMW part.
	h) Engine, speed characteristics not O.K.	h) Eliminate causes according to engine test.
	i) Engine management not OK (particularly on diesel engine).	i) Check engine control unit.
Clutch releases poorly (Gear difficult to engage)
Clutch does not separate (Gear cannot be engaged)	a) Lining of clutch plate broken.	a) Replace clutch plate Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	b) Lining rusted onto flywheel.	b) Evenly sand flywheel with sandpaper (120-180 grain) and replace clutch plate.
	c) Guide bearing for transmission input shaft in crankshaft defective.	c) Replace guide bearing in crankshaft.
	d) Leak in clutch hydraulic system.	d) Replace faulty parts and bleed clutch hydraulics Refer to BLEEDING CLUTCH HYDRAULIC SYSTEM .
	e) Tangential leaf springs of clutch bent down.	e) Replace clutch Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	f) Release unit binds on guide sleeve.	f) Clean guide sleeve, remove and install release unit Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .

TROUBLESHOOTING CHART

Fault	Cause	Remedy
Clutch noise	a) Imbalance of clutch and clutch plate too great.	a) Replace clutch/clutch plate Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	b) Torsional-vibration damper defective.	b) Replace clutch plate Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) . or if necessary replace dual-mass flywheel,
	c) Release unit defective.	c) Replace release unit Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .
	d) Guide bearing for transmission input shaft in crankshaft defective.	d) Replace guide bearing in crankshaft.
	e) Clutch rivet connection loose.	e) Replace clutch Refer to REMOVING AND INSTALLING/REPLACING CLUTCH (SAC 240) .