21 21 500 Removing and installing/replacing clutch (SAC)

WARNING: This page is about a different car, the 2010 BMW 550i, 2009 BMW 550i, and 2008 BMW 550i. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

11 9 260
11 9 263
11 9 264
11 9 265. See ENGINE - TIGHTENING TORQUES .
21 2 141
21 2 170
21 2 180
21 2 201
21 2 230
21 2 250. See CLUTCH - SPECIAL TOOLS .

Necessary preliminary tasks:

Remove transmission. MANUAL TRANSMISSION - REPAIR INSTRUCTIONS

Installation:

Screws must be replaced.

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

M54/M57/M57TU/N52/N52K/N53/S54 only:

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

Fig 1: Identifying Special Tool (11 9 265) And (11 9 260)

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N62 only:

Block flywheel with special tools 11 9 260 , 11 9 263 and 11 9 264 .

Fig 2: Identifying Special Tool (11 9 260), (11 9 263) And (11 9 264)

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Release screws and remove clutch from flywheel.

Installation:

Clean flywheel and check for wear and damage.

Replace damaged flywheel.

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

Fig 3: Locating Clutch Plate Screws

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

Installation:

Screws must be replaced.

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

Insert special tool 21 2 180 in clutch.

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: Identifying Special Tool (21 2 180)

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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 (1)

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

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

Fig 6: Identifying Knurled Screw And Spindle Screw

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NOTE: Insert special tool 21 2 170 only in area of bores for dowel pins.

Centre clutch plate (1) with special tool in dual-mass flywheel.

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: Centering Clutch Plate With Special Tool

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SPECIAL TOOL REFERENCE CHART

Special tool	Transmission
21 2 201	GS6-37BZ
21 2 230	GS6-53DZ/BZ
21 2 141	S5D 390Z
21 2 250	GS6-17BG

Fit clutch (1) to flywheel.

Tightening torque 21 21 1AZ. See CLUTCH - TIGHTENING TORQUE .

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

Fig 8: Identifying Dowel Pins And Clutch

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Release spindle (1) until load is fully removed from diaphragm spring. Remove special tools 21 2 170 and 21 2 180.

Fig 9: Releasing Spindle (1)

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

Fig 10: Identifying Clutch Plate Tool

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Installing removed clutch with new clutch plate:

Installation:

Screws must be replaced.

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

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).

Fig 11: Identifying Special Tool (21 2 180)

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

Fig 12: Locking Hooks

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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 13: Identifying Knurled Screw And Spindle Screw

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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).

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: Screwing Spindle

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Centre clutch plate (1) with special tool.

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.

SPECIAL TOOL REFERENCE CHART

Special tool	Transmission
21 2 201	GS6-37BZ
21 2 230	GS6-53DZ/BZ
21 2 141	S5D 390Z
21 2 250	GS6-17BG

Fig 15: Centering Clutch Plate With Special Tool

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Fit clutch (1) to flywheel.

Tightening torque, 21 21 1AZ. See CLUTCH - TIGHTENING TORQUE .

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

Fig 16: Identifying Dowel Pins And Clutch

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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 17: Releasing Spindle

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

Fig 18: Identifying Clutch Plate Tool

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Installing new clutch

IMPORTANT: Locking piece may only-be removed clutch is screwed down!

Installation:

Screws must be replaced.

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

Centre clutch plate (1) with special tool.

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: Centering Clutch Plate With Special Tool

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SPECIAL TOOL REFERENCE CHART

Special tool	Transmission
21 2 201	GS6-37BZ; GS 6-17BG
21 2 230	GS6-53DZ/BZ
21 2 141	S5D 390Z
21 2 250	GS6-17BG

Fit clutch to flywheel.

Tightening torque 21 21 1AZ. See CLUTCH - TIGHTENING TORQUE .

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

Fig 20: Identifying Dowel Pins (1)

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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: Unscrewing Locking Piece

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

Fig 22: Identifying Clutch Plate Tool

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