21 21 500 Removing and installing or replacing clutch (SAC 350)

Special tools required :

11 9 260
11 9 265
21 2 170
21 2 180
21 2 250
21 2 270
21 2 200

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 .

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

Fig 1: Removing Transmission

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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 openings of pressure spring.

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: Pressing Special Tool (21 2 180)

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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: Screwing Spindle

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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: Removing Self-Adjusting Clutch Bolts 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 Flywheel Clutch Disc

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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: Checking Clutch Disc For Wear

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When installing the removed self-adjusting clutch and clutch disc, observe the following procedure .

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.

IMPORTANT: Install clutch disc in correct position.
Note designation for "engine side"/"transmission side".
Handle clutch disc with care. Do not touch surfaces of friction linings.

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

Fig 9: Installing Center Clutch Disc

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NOTE: Fit special tool 21 2 170 only in area of bore holes for dowel pins.

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: Mounting Self-Adjusting Clutch On Flywheel

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

Fig 11: Removing Spindle And Diaphragm Spring

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

Fig 12: Removing Special Tool (21 2 170) From Self-Adjusting Clutch

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

Fig 13: Removing Special Tool (21 2 180) From Self-Adjusting Clutch

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

Fig 14: Removing Special Tool From Clutch Disc

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Installing removed clutch with new clutch disc :

Installation note :

Screws must be replaced.

IMPORTANT: Before installing a used clutch with a new clutch disc, always reset adjusting ring in new position.

IMPORTANT: Install clutch disc in correct position.
Note designation for "engine side"/"transmission side".
Handle clutch disc with care. Do not touch surfaces of friction linings.

Center clutch disc (1) with special tool.

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

Fig 15: Installing Center Clutch Disc

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Mount self-adjusting clutch (1) to flywheel.

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: Mounting Self-Adjusting Clutch On Flywheel

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

Fig 17: Removing Spindle And Diaphragm Spring

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

Fig 18: Removing Special Tool (21 2 170) From Self-Adjusting Clutch

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

Fig 19: Removing Special Tool (21 2 180) From Self-Adjusting Clutch

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

Fig 20: Removing Special Tool From Clutch Disc

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Installing new clutch

IMPORTANT: Locking element may only be removed with the clutch screwed down!

Installation note :

Screws must be replaced.

IMPORTANT: Handle clutch disc with care. Do not touch surfaces of friction linings.
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 21 2 250	GS6-17BG

Fig 21: Installing Center Clutch Disc

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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 Clutch Dowel Pins

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Carefully unscrew stop (1) in clockwise or anticlockwise direction using a hexagon socket wrench AF 14 (2).

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

Fig 23: Removing Stop Clockwise/Anticlockwise

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

Fig 24: Removing Special Tool From Clutch Disc

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