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

WARNING: This page is about a different car, the 2011 BMW M3, 2010 BMW M3, 2009 BMW M3, and 2008 BMW M3. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required

IMPORTANT: After completing work:

Check TRANSMISSION FLUID LEVEL .
Use only the approved gear oil for dual clutch transmission.
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 PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION) .

IMPORTANT: Twin-clutch gearbox must be on neutral (position "N") prior to removal of clutch or gear box!
Changing gears is only possible with engine running!
To prevent gearbox oil from escaping, move gearbox into an upright position 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 KEY .
Special tool 23 0 400 KEY must be pushed in entirely and rest flush on clutch cage.
Twist gearbox input shafts towards each other if necessary.

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

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Push parking lock lever (1) as far upwards as possible and secure with cable straps (2).

Fig 2: Identifying Parking Lock Lever And Cable Strap

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

Check clearance with a suitable tool.

Fig 3: Rotating Drive Shaft

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Insert special tool 23 0 400 KEY and release clutch by rotating counter-clockwise (approx. 8 turns).

Pull clutch out of housing.

Installation note:

Put gearbox in an upright position.

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

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

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

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

Fig 4: Installing Clutch Using 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 the piston rings (1) and the needle bearings (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.