BMW 318/325/M3/525/535/M5 1989-1993 Repair Information

Clutch Assembly



  1. Disconnect the negative battery cable. Raise and safely support the vehicle. Remove the heat shield and then the mounting bolts. Disconnect the speed and reference mark sensors at the flywheel housing. Mark the plugs for reinstallation.
  3. Remove the transmission.
  5. If equipped with a 265/6 transmission (without an integral clutch housing), remove the clutch housing. A Torx® socket is required.
  7. Prevent the flywheel from turning, using a locking tool.
  9. Loosen the mounting bolts one after another gradually, 1-1 1 / 2 turns at a time, to relieve tension from the clutch.
  11. Remove the mounting bolts, clutch, and drive plate. Note the mounted direction of the drive plate for installation. Coat the splines of the transmission input shaft with Molykote® Long-term 2 for standard flywheels, or Microlube® GL 261 for dual mass flywheels, or equivalent. Make sure the clutch pilot bearing, located in the center of the crankshaft, turns easily. Replace the pilot bearing, if necessary.
  13. Check the clutch driven disc for excess wear or cracks. Check the integral torsional damping springs, used with standard flywheels only, for tight fit. Dual mass flywheels use a solid clutch disk. Inspect the rivets to make sure they are all tight. Check the flywheel to make sure it is not scored, cracked, or burned, even at a small spot. Use a straight edge to make sure the contact surface is true. Replace any defective parts.

To install:
  1. To install, fit the new clutch plate and disc in place and install the mounting bolts.
  3. When installing the clutch retaining bolts turn them in gradually to evenly tighten the clutch disc and to prevent warpage. Except for the S38 engine, torque M8-8.8 bolts to 17 ft. lbs. (24 Nm) and M8-10.9 bolts to 25 ft. lbs. (35 Nm). On the S38 engine torque the bolts to 24.5 ft. lbs. (34 Nm) with the dowel sleeves installed.
  5. Install the clutch housing, if separate. Torque the M8 bolts to 19.5 ft. lbs. (27 Nm), the M10 bolts to 37 ft. lbs. (51 Nm) and the M12 bolts to 62 ft. lbs. (86 Nm). Install the transmission.
  7. If equipped, install the speed and reference mark sensors. Install the heat shield.