21 21 500 Removing and installing or replacing clutch (self-adjusting clutch)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2019 MINI Cooper, 2018 MINI Cooper, 2017 MINI Cooper, 2016 MINI Cooper, and 2015 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

Preliminary work needed:

Remove TRANSMISSION .

Removal:

Block the flywheel with Torx screw (1) and special tools 11 9 811 and 11 9 265 .

Fig 1: Blocking Flywheel With Torx Screw Or Special Tools (11 9 811) And (11 9 265)

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Insert special tool 2 288 166 in self-adjusting clutch.

NOTE: Locking hooks (1) of special tool 2288 166

must engage in recesses of self-adjusting clutch.

Fig 2: Locking Hooks Of Special Tool (2 288 166)

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Press special tool 2 288 166 together at handles (2) until stop and grip firmly.

At same time tighten down knurled screws (1).

Adjusting ring of self-adjusting clutch is now secured.

Fig 3: Pressing Special Tool (2 288 166) Together At Handles

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Fit special tool 21 2 170 with the pressure plate 2 288 165 and tighten down at knurled screw (1).

Fig 4: Fitting Special Tool (21 2 170) With Pressure Plate (2 288 165)

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Screw in spindle (1) until diaphragm spring (2) is pretensioned at stop.

Fig 5: Spindle And Diaphragm Spring

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Release the screws and remove the self-adjusting clutch with clutch disc from the flywheel.

Fig 6: Locating Self-Adjusting Clutch Screws

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IMPORTANT: Always replace clutch discs fouled e.g. by oil, cleaning agent.
Check the clutch disc for damage and contact 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 connector

Closing head
Swage head

Fig 7: Closing Head And Swage Head

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Replace the clutch disc with the self-adjusting clutch if the 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.

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.

Installation (reinstalling 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 2 358 471 .

Fig 8: Centering Clutch Disc With Special Tool (2 358 471)

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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.

Part: Replace screws.

Tightening torque: 21 21 1AZ .

Fig 9: Self-Adjusting Clutch And Dowel Pins

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

Fig 10: Releasing Spindle

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

Fig 11: Releasing Knurled Screw

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Release knurled screws (1) and remove special tool 2 288 166 from self-adjusting clutch.

Fig 12: Removing Special Tool (2 288 166) From Self-Adjusting Clutch

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2 358 471 Withdraw special tool from clutch disc with aid of accompanying screw (1).

Fig 13: Removing Special Tool (2 358 471) From Clutch Disc With Aid Of Accompanying Screw

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Installation (installing 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 DISENGAGEMENT MODULE included in the new replacement clutch set and the new guide sleeve must be installed.

Check the ball hub and REPLACE it if necessary.

IMPORTANT: Different ball hubs (A) and (B) may be installed in vehicles until 12/2016!
Ball hubs differ in length, diameter and visually by the flat portion (1)! See Fig 14 graphic.
It must be ensured that the same ball hub is installed again!
Non-compliance may lead to damage to the clutch and transmission!

Fig 14: Checking Ball Hubs Diameter

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Center clutch disc (1) with special tool 2 358 471 .

Fig 15: Centering Clutch Disc With Special Tool (2 358 471)

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Push the self-adjusting clutch on the dowel pins (1) located in the flywheel and tighten the screws.

Part: Replace screws.

Tightening torque: 21 21 1AZ .

Fig 16: Locating Dowel Pins And Screws

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IMPORTANT: The stop (1) may be removed only with screw-mounted self-adjusting clutch.

Carefully unscrew stop (1) clockwise or counterclockwise using a size-14 Allen wrench (2).

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

Fig 17: Unscrewing Stop Clockwise Or Counterclockwise Using Size-14 Allen Wrench

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2 358 471 Withdraw special tool from clutch disc with aid of accompanying screw (1).

Fig 18: Removing Special Tool (2 358 471) From Clutch Disc With Aid Of Accompanying Screw

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