21 21 500 Removing and installing or replacing clutch (SAC 240)

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Special tools required:

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 .

Identification SAC clutch ø 240 mm (self-adjusting clutch):

3 openings each with a pressure piece (1) of adjustment ring and a pressure spring (2)

NOTE: Figure shows new position of the thrust pieces.

Fig 1: Locating Pressure Spring

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Lock flywheel with special tool 11 9 260 .

Fig 2: Identifying Special Tool 11 9 260

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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 recesses of self-adjusting clutch.

Fig 3: Identifying Special Tool 21 2 180

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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 4: Adjusting Ring

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

Fig 5: Tightening Knurled Screw

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Screw in spindle (1) until diaphragm spring (2) is tensioned up to stop.

Fig 6: Removing 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 7: Removing Bolts And Clutch 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 8: Identifying 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 9: Measuring Clutch Disc Lining Protrusion

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Reinstall the previously removed self-adjusting clutch and clutch disc:

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.

Special tool	Transmission
21 2 141	S6S 420G; S6S 560G; S5D 390Z
21 2 142	S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 200	GS6-37BZ; GS6-17BG
21 2 230	GS6-53DZ/BZ, GS6-45DZ
21 2 250	GS6-17BG

Fig 10: Identifying Special Tool 21 2 250

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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 11: Identifying Clutch And Dowel Pins

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

Fig 12: Releasing Spindle

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

Fig 13: Releasing Knurled Screw

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

Fig 14: Releasing Knurled Screw

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

Fig 15: Identifying Special Tool 21 2 250

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Install removed self-adjusting clutch with new clutch disc:

Installation note:

Screws must be replaced.

IMPORTANT: Before installing a self-adjusting clutch which has been in service with a new clutch disc: always reset adjusting ring in new position.

Fig 16: Identifying Special Tool 21 2 141

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Special tool	Transmission
21 2 141	S6S 420G; S6S 560G; S5D 390Z
21 2 142	S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 200	GS6-37BZ; GS6-17BG
21 2 230	GS6-53DZ, GS6-45DZ
21 2 250	GS6-17BG

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 21 21 1AZ .

Fig 17: Identifying Clutch And Dowel Pins

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

Fig 18: Releasing Spindle

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

Fig 19: Releasing Knurled Screw

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

Fig 20: Releasing Knurled Screw

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

Fig 21: Identifying Special Tool 21 2 250

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Install new self-adjusting clutch:

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 (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 2 141	S6S 420G; S6S 560G; S5D 390Z
21 2 142	S5D 200G; S5D 250G; S5D 260Z; S5D 310Z
21 2 200	GS6-37BZ; GS6-17BG
21 2 230	GS6-53DZ, GS6-45DZ
21 2 250	GS6-17BG

Fig 22: Identifying Special Tool 21 2 141

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Slide self-adjusting clutch onto dowel pin (1) located in flywheel and screw on.

Tightening torque: 21 21 1AZ .

Fig 23: Locating Flywheel Dowel Pin

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

IMPORTANT: 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.

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

Fig 24: Removing Stop Clockwise/Anticlockwise With Hexagon Socket Wrench SW14

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

Fig 25: Identifying Special Tool 21 2 250

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