Removal & Installation (X5)

WARNING: This page does not describe the selected car, but rather 12 other vehicles, including the 2006 BMW X5, 2006 BMW X3, 2005 BMW X5, 2005 BMW X3, and 2005 BMW 645Ci. However, it is still accessible from the selected car via links, so may be relevant.

Remove transmission. See appropriate MANUAL TRANSMISSION removal article. To identify clutch, note 3 openings each with a pressure piece (1) of a ring and a pressure spring (2).

Fig 1: Identifying Clutch
Courtesy of BMW OF NORTH AMERICA, INC.
On 6-cylinder engine, block flywheel (1) with special tool 11 2 170. See Fig 2. On 8-cylinder engine, lock flywheel with special tool 11 2 070. See Fig 3. Unfasten bolts and remove SAC from flywheel. See Fig 4. Do not use a special tool to detach SAC clutch from flywheel. Remove clutch plate (1) from flywheel. See Fig 5. Clean flywheel, check for wear and damage. Replace damaged flywheel. Check grooved ball bearing in crankshaft for ease of movement and tightness and if necessary replace grooved ball bearing. Always replace clutch plates fouled by oil or cleaning agent. Check clutch plate for damage and friction rust in hub profile and replace if necessary. Check clutch disk for wear and measure lining protrusion at lining rivets at closing head (A) in each case. Rivet connection: A = closing head, B = swage head. See Fig 6. Replace clutch plate if lining protrusion at closing head (A) is less than 1 mm. Push clutch disk onto the cleaned transmission input shaft and check for easy movability. Do not clean SAC clutch with high pressure cleaner or washing machine as this may impair function of adjustment unit. Clean friction surface only. Check SAC for wear and damage and replace if necessary.

Fig 2: Blocking Flywheel (6-Cylinder)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 3: Blocking Flywheel (8-Cylinder)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 4: Removing SAC From Flywheel
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 5: Removing Clutch Plate From Flywheel
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 6: Identifying Closing Head & Swage Head
Courtesy of BMW OF NORTH AMERICA, INC.
To reinstall removed SAC clutch and clutch plate, set SAC clutch (1) down on a clean surface. See Fig 7. Install special tool 21 2 180 in SAC clutch (1). Locking hooks (1) of special tool 21 2 180 must engage in openings in SAC clutch. See Fig 8. Press special tool (21 2 180) together at handles (1) as far as it will go and grip firmly. At same time tighten down knurled screws (2). See Fig 9. Adjustment ring of SAC clutch is now secured in its original position (wear position). Do not reset adjustment ring to new position. Insert special tool 21 2 170 only in area of bores for dowel pins. See Fig 10. Fit special tool 21 2 170 and tighten down at knurled screw (1). See Fig 11. Screw in spindle (1) until diaphragm spring (2) is pretensioned up to stop. See Fig 12. Handle clutch disk carefully, using care to not touch surfaces of friction pads. Install clutch plate in correct position. Note designation for "engine side" and "transmission side". Center clutch plate (1) with special tool. See Fig 13. On vehicles manufactured from 4/03, note color marking when fitting clutch with balance marking. Position color marking (1) on dual-mass flywheel and color marking (2) on clutch pressure plate as closely as possible to each other. See Fig 14. Maximum possible angle error is 60 degrees. On all vehicles, fit SAC clutch (1) on flywheel. Pay attention to dowel pins (2). See Fig 15. SAC clutch (1) must be secured by way of dowel pins (2).

Fig 7: Setting SAC Clutch Down On A Clean Surface
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 8: Identifying Locking Hooks Of Special Tool
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 9: Pressing Special Tool At Handles & Tightening Knurled Screws
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 10: Identifying Area Of Bores For Dowel Pins
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 11: Installing Special Tool & Tightening At Knurled Screw
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 12: Screwing In Spindle Until Diaphragm Spring Is Pretensioned
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 13: Centering Clutch Plate With Special Tool
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 14: Positioning Color Marking
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 15: Identifying Clutch & Dowel Pins
Courtesy of BMW OF NORTH AMERICA, INC.
Insert screws and tighten down. Release spindle (1) until tension is completely removed from diaphragm spring (2). See Fig 16. Release knurled screw (1) and remove special tool (21 2 180). See Fig 17. Release knurled screws (2) and remove special tool (21 2 180) from SAC clutch. See Fig 18. Withdraw special tool from clutch plate with aid of accompanying screw (1). See Fig 19.

Fig 16: Releasing Spindle Until No Tension Is Present At Diaphragm Spring
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 17: Releasing Knurled Screw & Special Tool From Clutch
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 18: Releasing Knurled Screws & Special Tool
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 19: Removing Special Tool From Clutch Plate Using
Courtesy of BMW OF NORTH AMERICA, INC.
Before installing an SAC clutch which has been in service with a new clutch plate, always reset adjustment ring in new position. Set SAC clutch down on a clean surface. Install special tool (21 2 180) in SAC clutch (1). See Fig 20.

Fig 20: Installing Special Tool In SAC Clutch
Courtesy of BMW OF NORTH AMERICA, INC.
Locking hooks (1) of special tool (21 2 180) must engage in openings in SAC clutch. See Fig 21. Insert special tool (21 2 170) only in area of bores for dowel pins. See Fig 22. Fit special tool (21 2 170) and tighten down at knurled screw (1). See Fig 23. Screw in spindle (1) until adjustment ring of SAC 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. See Fig 24. At same time tighten down knurled screws (2). Adjustment ring of SAC clutch is now secured in new position. See Fig 25. Screw in spindle (1) until diaphragm spring (2) is tensioned to stop. See Fig 26. Handle clutch plate with care, do not touch surfaces of friction linings. Install clutch plate in correct position. Pay attention to text "engine end" and "transmission side".

Fig 21: Ensuring Locking Hooks Engage In Openings In SAC Clutch
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 22: Inserting Special Tool Only In Area Of Bores For Dowel Pins
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 23: Installing Special Tool & Tightening Down At Knurled Screw
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 24: Screwing In Spindle Until Adjustment Ring Of SAC Clutch Can Be Turned With Special Tool At Handles
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 25: Securing Adjustment Ring Of SAC Clutch In New Position
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 26: Screwing In Spindle Until Diaphragm Spring Is Tensioned To Stop
Courtesy of BMW OF NORTH AMERICA, INC.
Center clutch plate (1) with special tools. See Fig 27. On vehicles manufactured from 4/03, note color marking when fitting clutch with balance marking. Position color marking (1) on dual-mass flywheel and color marking (2) on clutch pressure plate as closely as possible to each other. See Fig 14. Maximum possible angle error is 60 degrees. Fit SAC clutch (1) on flywheel. Pay attention to dowel pins (2). See Fig 28. SAC clutch (1) must be secured by way of dowel pins (2). Install retaining screws of SAC clutch and tighten down. Release spindle (1) until tension is completely removed from diaphragm spring (2). See Fig 29. Release knurled screw (1) and remove special tool (21 2 170) from SAC clutch. See Fig 30. Release knurled screws (2) and remove special tool (21 2 180) from SAC clutch. See Fig 31. Withdraw special tool from clutch plate with aid of accompanying screw (1). See Fig 32.

Fig 27: Centering Cutch Plate With Special Tools
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 28: Fitting Clutch On Flywheel & Noting Location Of Dowel Pins
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 29: Releasing Spindle Until Tension Is Removed
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 30: Releasing Knurled Screw
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 31: Releasing Knurled Screws
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 32: Withdrawing Special Tool From Clutch Plate
Courtesy of BMW OF NORTH AMERICA, INC.
When installing new SAC, handle clutch disk carefully. Do not touch surfaces of friction pads. Install clutch plate (1) in correct position. Note designation for "engine side" and "transmission side". Center clutch plate (1) with special tools. See Fig 33. Push SAC clutch onto dowel pins (1) located in flywheel and screw down. See Fig 34. Locking piece (1) may only be removed with SAC screw-mounted clutch. Carefully unscrew locking piece (1) clockwise or counterclockwise with a hexagon socket wrench (2). See Fig 35. A slight snapping of the plate spring while unscrewing is possible. Withdraw special tool (1) from clutch plate with aid of accompanying screw (2). See Fig 36.

Fig 33: Centering Clutch Plate With Special Tools
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 34: Pushing SAC Clutch Onto Dowel Pins
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 35: Unscrewing Locking Piece
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 36: Removing Special Tool From Clutch Plate
Courtesy of BMW OF NORTH AMERICA, INC.