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

WARNING: This page is about a different variant/trim than selected.

Special tools required:

IMPORTANT: Do not clean the Self-adjusting clutch and the flywheel with a pressure washer or washing machine, otherwise the function of adjusting unit and damping springs is no longer guaranteed.
Clean friction surface only.
Check self-adjusting clutch for wear and damage and replace as necessary.

Necessary preliminary tasks:

Remove transmission . See 23 00 017 REMOVING AND INSTALLING TRANSMISSION (GS6-17BG) N20 or 23 00 028 REMOVING AND INSTALLING TRANSMISSION (GS6-17BG) ALL-WHEEL VEHICLE DRIVE .

Lock flywheel with special tool 11 9 260 .

Fig 1: Identifying Special Tool (11 9 260)

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Insert special tool 21 2 180 in self-adjusting clutch.

NOTE: Locking hooks (1) of special tool 21 2 180 must engage in recesses of self-adjusting clutch.

Fig 2: Inserting Special Tool (21 2 180) In Self-Adjusting Clutch

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Press special tool 21 2 180 together at handles (1) up to limit position and grip firmly.

At same time tighten down knurled screws (2).

Adjusting ring of self-adjusting clutch is now secured.

Fig 3: Adjusting Ring

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

Fig 4: Tightening Knurled Screw

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Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.

Fig 5: Identifying Spindle Screw

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Remove bolts and remove self-adjusting clutch from flywheel.

Installation note:

Screws must be replaced.

Jointing torque and angle of rotation must be observed without fail.

Fig 6: Locating Bolts And Clutch From Flywheel

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Remove clutch disc (1) from flywheel.

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 .

Fig 7: Identifying Clutch Disc And Flywheel

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

Check the clutch disc for damage and frictional corrosion in the hub profile and replace if necessary.

Check clutch disc for wear:

Measure lining protrusion at lining rivets at closing head (A) in each case.

NOTE: Rivet connection

Closing head
Swage head

Replace clutch disc 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.

Fig 8: Measuring Clutch Disc Lining Protrusion

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Observe the following procedure when installing the removed self-adjusting clutch and clutch disc.

IMPORTANT: Handle clutch disk carefully, do not touch surfaces of friction pads.
Clean friction surfaces of the flywheel and the pressure plate with BMW-approved brake cleaner.
Install clutch disc in correct position.
Note designation for "engine side"/"transmission side".

Center clutch disc (1) with special tool in dual-mass flywheel.

Special tool	Transmission
21 2 270	GS6-37DZ
21 2 200	GS6-17BG
21 2 250

Fig 9: Identifying Center Clutch Disc With Special Tool In Dual-Mass Flywheel

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Mount self-adjusting clutch (1) on flywheel together with special tools.

Pay attention to dowel pins (2).

Self-adjusting clutch (1) must be secured by way of dowel pins (2).

Install and tighten down screws.

Tightening torque: 21 21 1AZ .

Fig 10: Tightening Flywheel Screws

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

Fig 11: Releasing Spindle

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Release knurled screw (1) and remove special tool 21 2 170 from self-adjusting clutch.

Fig 12: Releasing Knurled Screw

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Release knurled screws (2) and remove special tool 21 2 180 from self-adjusting clutch.

Fig 13: Releasing Knurled Screw

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

Fig 14: Identifying Clutch Disc Screw

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Install removed self-adjusting clutch with new clutch disc:

Installation note:

Screws must be replaced.

IMPORTANT: Before installing a self-adjusting clutch which has been in service with a new clutch disc: always reset adjusting ring in new position.

Center clutch disc (1) with special tool.

Special tool	Transmission
21 2 270	GS6-37DZ
21 2 200	GS6-17BG
21 2 250

Fig 15: Identifying Center Clutch Disc With Special Tool In Dual-Mass Flywheel

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Mount self-adjusting clutch (1) on flywheel together with special tools.

Pay attention to dowel pins (2).

Self-adjusting clutch (1) must be secured by way of dowel pins (2).

Insert and tighten mounting bolts for self-adjusting clutch.

Tightening torque: 21 21 1AZ .

Fig 16: Tightening Flywheel Screws

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

Fig 17: Releasing Spindle

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Release knurled screw (1) and remove special tool 21 2 170 from self-adjusting clutch.

Fig 18: Releasing Knurled Screw

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Release knurled screws (2) and remove special tool 21 2 180 from self-adjusting clutch.

Fig 19: Releasing Knurled Screw

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

Fig 20: Identifying Clutch Disc Screw

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Install new self-adjusting clutch:

IMPORTANT: Handle clutch disk carefully, do not touch surfaces of friction pads.
Clean friction surfaces of the flywheel and the pressure plate with BMW-approved brake cleaner.
Install clutch disc (1) in correct position.
Note designation for "engine side"/"transmission side".
The CLUTCH OPERATOR contained in the new replacement clutch set absolutely must be installed.

Center clutch disc (1) with special tool.

Special tool	Transmission
21 2 270	GS6-37DZ
21 2 200	GS6-17BG
21 2 250

Fig 21: Identifying Center Clutch Disc With Special Tool In Dual-Mass Flywheel

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Slide self-adjusting clutch onto dowel pin (1) located in flywheel and screw on.

Tightening torque: 21 21 1AZ .

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

Fig 22: Locating Flywheel Dowel Pin

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IMPORTANT: Stop (1) may only be removed with self-adjusting clutch screw-mounted.

Carefully unscrew stop (1) clockwise or anti-clockwise using a size 14 (2) hexagon socket wrench.

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

Fig 23: Removing Stop Clockwise/Anticlockwise With Hexagon Socket Wrench

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

Fig 24: Identifying Clutch Disc Screw

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