28 40 010 Removing and installing or replacing twin clutch (GS7D36SG)

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

IMPORTANT: After completing work:

Check oil level ..
Use only the DCTF-1 Pentosin (P/N 83 22 2 147 477) approved transmission oil. .
Perform clutch adaptation (Service Functions).
Teach in valve characteristics (Service Functions).

Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox.

IMPORTANT: Read and comply with notes on ESD PROTECTION (ELECTRO STATIC DISCHARGE) .

IMPORTANT: Twin-clutch gearbox must be on neutral (position "N") prior to removal of clutch or gear box!
Gear shifts are only possible with the engine running.
To prevent the transmission oil from spilling out, set the gearbox upright before removing the twin clutch.

Necessary preliminary tasks

Remove twin-clutch gearbox
Remove clutch cover

IMPORTANT: The clutch cage can only be removed and installed with special tool 23 0 400 .
Special tool 23 0 400 must be pushed in entirely and rest flush on clutch cage.
If necessary, turn the gearbox input shafts relative to each other.

Fig 1: Installing Clutch Cage Using Special Tool (23 0 400)

Courtesy of BMW OF NORTH AMERICA, INC.

Push parking lock lever (1) all the way up and secure it with cable strap (2).

Fig 2: Identifying Parking Lock Lever And Cable Strap

Courtesy of BMW OF NORTH AMERICA, INC.

Rotate drive shaft (1) until holes (2) are directly visible.

Check clearance with a suitable tool.

Fig 3: Identifying Drive Shaft With Holes

Courtesy of BMW OF NORTH AMERICA, INC.

Install special tool 23 0 400 and turn anticlockwise to release clutch (approx. 8 turns).

Pull clutch out of housing.

Installation note:

Set gearbox upright.

The clutch is correctly installed if the oil pump gear turns.

Install the clutch with special tool 23 0 400 while constantly rotating.

Turn clockwise up to stop, then screw down to torque.

Tightening torque, see 28 40 1AZ in 28 40 DOUBLE CLUTCH GEARBOX (DKG) .

Fig 4: Pulling Clutch From Housing Special Tool (23 0 400)

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Warning: Installing the clutch may involve the danger of injury!

Installation note:

Under no circumstances are hammers or other pounding tools to be used when installing the clutch.

The clutch must be slid over the piston rings and onto the clutch support.

IMPORTANT: When reinstalling the clutch, check that piston rings (1) and needle bearing (2) are present and correctly seated on the clutch support.
Mount clutch carefully to clutch support/do not tilt, to avoid damaging the piston rings (1).

Fig 5: Identifying Piston Rings And Needle Bearing

Courtesy of BMW OF NORTH AMERICA, INC.