21 21 500 Removing and installing or replacing clutch (SAC 240)
Special tools required:
- 11 9 260
- 21 2 141
- 21 2 142
- 21 2 170
- 2 12 180
- 21 2 200
- 21 2 230
- 21 2 250
- 2 288 165
Attention!
Do not clean the self-adjusting clutch and flywheel with high pressure cleaner or a washing machine, as the proper function of the adjustment unit and damping springs can then no longer be guaranteed.
Clean friction surface only.
Check self-adjusting clutch for wear and damage and replace if necessary.
Necessary preliminary tasks:
- Remove the TRANSMISSION .
Identification of self-adjusting clutch 0 240 mm:
- 3 openings each with a pressure piece (1) of adjustment ring and a pressure spring (2)
Removal:
Lock flywheel with special tool 11 9 260 .
Insert special tool 21 2 180 in self-adjusting clutch.
Press special tool 21 2 180 together at handles (2) until limit position and grip firmly.
At same time tighten down knurled screws (1).
Adjusting ring of self-adjusting clutch is now secured.
Fit special tool 21 2 170 with the pressure plate 2 288 165 and tighten down at knurled screw (1).
Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.
Remove bolts and remove self-adjusting clutch from flywheel.
Attention!
Do not use a special tool to detach the self-adjusting clutch from the flywheel.
Installation note:
Screws must be replaced.
Jointing torque and angle of rotation must be observed without fail. see TIGHTENING SPECIFICATIONS for more details.
Remove clutch disc (1) from flywheel.
Clean flywheel, check for wear and damage.
Replace the DAMAGED FLYWHEEL .
Attention!
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.
- 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.
Attention!
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.
Reinstall the previously removed self-adjusting clutch and clutch disc:
Attention!
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.
| Special tool | Transmission |
|---|---|
| 21 2 200 | GS6-17 BZ/DZ |
| 21 2 230 | GS6-45 BZ/DZ |
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, refer to: 21 21 1AZ .
Release spindle (1) until load is fully removed from diaphragm spring (2).
Release knurled screw (1) and remove special tool 21 2 170 2 288 165 using the pressure plate from self-adjusting clutch.
Release knurled screws (1) and remove special tool 21 2 180 from self-adjusting clutch.
21 2 230 Withdraw special tool from clutch disc with aid of accompanying screw (1).
Required reworking:
- Install the TRANSMISSION .
Install removed self-adjusting clutch with new clutch disc:
Attention!
Before installing a self-adjusting clutch which has been in service with a new clutch disc: always reset adjusting ring in new position.
Attention!
Handle clutch disk carefully, do not touch surfaces of friction pads.
Install clutch disc in correct position.
Note designation for "engine side"/"transmission side".
Center clutch disc (1) with special tool.
| Special tool | Transmission |
|---|---|
| 21 2 200 | GS6-17 BZ/DZ |
| 21 2 230 | GS6-45 BZ/DZ |
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, refer to: 21 21 1AZ .
Release spindle (1) until load is fully removed from diaphragm spring (2).
Release knurled screw (1) and remove special tool 21 2 170 2 288 165 using the pressure plate from self-adjusting clutch.
Release knurled screws (1) and remove special tool 21 2 180 from self-adjusting clutch.
21 2 230 Withdraw special tool from clutch disc with aid of accompanying screw (1).
Required reworking:
- Install the TRANSMISSION .
Install new self-adjusting clutch:
Attention!
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 2 200 | GS6-17 BZ/DZ |
| 21 2 230 | GS6-45 BZ/DZ |
Slide self-adjusting clutch onto dowel pin (1) located in flywheel and screw on.
Part: Replace screws.
Tightening torque, refer to: 21 21 1AZ .
Attention!
Stop (1) may only be removed with self-adjusting clutch screw-mounted.
Carefully unscrew stop (1) clockwise or anticlockwise using a size 14 (2) hexagon socket wrench.
21 2 230 Withdraw special tool from clutch disc with aid of accompanying screw (1).
Required reworking:
- Install the TRANSMISSION .