Removing and installing or replacing clutch (self-adjusting clutch) (Cooper S)

Special tools required: 

• 11 9 811
• 11 9 265
• 22 88 166
• 21 2 170
• 2 288 165
• 2 358 470
• 2 358 471

Preliminary work needed: 

• Remove TRANSMISSION .

Removal: 

Block flywheel with transmission bolt (1) and special tools 11 9 811 and 11 9 265.

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Screw in spindle (1) until diaphragm spring (2) is pre-tensioned at stop.

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Attention! 

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.

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.

Courtesy of BMW OF NORTH AMERICA, INC.

Attention! 

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): 

Attention! 

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 2 358 470 or 2 358 471.

Courtesy of BMW OF NORTH AMERICA, INC.

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 .

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Withdraw special tool 2 358 470 or 2 358 471 from clutch disc with aid of accompanying screw (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work: 

• Install TRANSMISSION .

Installation (installing new self-adjusting clutch): 

Attention! 

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 SLEEVEmust  be installed.

Check the BALL PIN  and replace it if necessary.

Attention! 

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 graphic.

It must be ensured that the same ball hub is installed again! 

Non-compliance may lead to damage to the clutch and transmission!

Courtesy of BMW OF NORTH AMERICA, INC.

Center clutch disc (1) with special tool 2 358 470 or 2 358 471.

Courtesy of BMW OF NORTH AMERICA, INC.

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 .

Courtesy of BMW OF NORTH AMERICA, INC.

Carefully unscrew stop (1) clockwise or counterclockwise using a WAF 14 hexagon socket wrench (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Withdraw special tool 2 358 470 or 2 358 471 from clutch disc with aid of accompanying screw (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Necessary reworking: 

• Install TRANSMISSION .