21 21 500 Removing And Installing/Replacing Clutch (SAC 240)

WARNING: This page is about a different car, the 2010 BMW 135i, 2009 BMW 135i, and 2008 BMW 135i. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

11 9 260
11 9 265
21 2 170
21 2 180
21 2 270

Necessary preliminary tasks:

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

M57T2/N57

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

N54

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

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

Fig 2: Identifying Block Flywheel With 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.

Fig 3: Identifying Flywheel Screws

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

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

Insert special tool 21 2 180 in clutch. See Fig 4.

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: Inserting Special Tool 21 2 180 In Clutch

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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 21 2 180

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Fit special tool 21 2 170 and tighten down at knurled screw (1). See Fig 6.

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

Fig 6: Identifying Special Tool 21 2 170

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NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins. Center clutch plate (1) with special tool 21 2 170.

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 Clutch Plate With Special Tool

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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: Removing Special Tools

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

Fig 10: Identifying Accompanying 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). See Fig 12.

Fig 11: Identifying Special Tool On Clutch

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NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings in clutch. See Fig 13.

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 12: Locking Hooks Of Special Tool 21 2 180

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Fig 13: Identifying Special Tool 21 2 170

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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). See Fig 14.

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: Pressing Special Tool 21 2 180

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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 Clutch Plate With Special Tool

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Fit clutch (1) to flywheel.

Tightening torque 21 21 1AZ .

Fig 16: Identifying Clutch And Dowel Pins

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

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

Remove special tools 21 2 170 and 21 2 180.

Fig 17: Removing Special Tools

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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 Clutch Plate With Special Tool

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Fit clutch to flywheel.

Tightening torque 21 21 1AZ .

Fig 20: Identifying Flywheel Dowel Pins

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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).

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

Fig 21: Removing Unscrew With Hexagon Socket Wrench

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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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