21 21 500 Removing and installing or replacing clutch (SAT 235)

Special tools required:

Necessary preliminary tasks:

Lock flywheel with special tool 11 9 590 .

Fig 1: Securing Crankshaft With Special Tool (11 9 590)

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fit special tool 21 2 170 and tighten down at knurled screw (2). Screw in spindle (3) (approx.6-8 mm) until diaphragm spring (4) is tensioned on stop.

Insert special tool 21 0 010 into recess (1) and disable readjustment of the clutch.

The special tool must remain in the position shown until the clutch is refitted.

Fig 2: Inserting Special Tool (21 0 010) Into Recess

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Only insert special tool 21 2 170 in the area of the riveting between pressure plate and spring on the cover.
Release screws and remove clutch from flywheel.

Installation note:

Clean flywheel and check for wear and damage.

Replace damaged flywheel.

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

Graphic similar.

Check clutch disc for wear:

Measure lining protrusion on transmission side.

Measure from rivet head (1).

The clutch disc must be replaced if the lining protrusion at the rivet head (1) is less than 1 mm.

Fig 3: Checking Clutch Disc For Wear

Courtesy of BMW OF NORTH AMERICA, INC.

Center clutch disc (1) with special tool 21 0 000 .

IMPORTANT: Install clutch disc in correct position.
Handle clutch disc with care. Do not touch surfaces of friction linings.

Fig 4: Centering Clutch Disc Using Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Fit clutch (1) to flywheel.

Tighten clutch screws crosswise.

Tightening torque 21 21 5AZ .

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

Fig 5: Installing Clutch On Flywheel Using Dowel Pins

Courtesy of BMW OF NORTH AMERICA, INC.

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

Remove special tools 21 2 170 and 21 0 000 .

Fig 6: Loosening Spindle

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Removing Special Tool From Clutch Disc Using Accompanying Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Installing new clutch

Vehicles up to model year 02/2013:

When fitting a new clutch, it is imperative that the over-center helper spring of the pedal mechanism is replaced at the same time.

IMPORTANT: Only insert special tool 21 2 170 in the area of the riveting between pressure plate and spring on the cover.

Fit special tool 21 2 170 to pressure plate and tighten at the knurled screw (1).

Screw in spindle (2) approx.10-12 mm) until diaphragm spring (3) is tensioned on stop.

The diaphragm spring must not be pressed too far.

Fig 8: Inserting Special Tool (21 2 170) Between Pressure Plate And Spring On Cover

Courtesy of BMW OF NORTH AMERICA, INC.

Center clutch disc (1) with special tool 21 0 000 .

IMPORTANT: Install clutch disc in correct position.
Handle clutch disc with care. Do not touch surfaces of friction linings.

Fig 9: Centering Clutch Disc Using Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Fit the pre-tensioned clutch.

Tighten clutch screws crosswise.

Tightening torque 21 21 5AZ .

Fig 10: Tightening Clutch Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Remove special tool 21 2 170 .

Fig 11: Removing Special Tool (21 2 170)

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 12: Removing Special Tool From Clutch Disc Using Accompanying Screw

Courtesy of BMW OF NORTH AMERICA, INC.