BMW Cars 1999-06

Driven Disc & Pressure Plate

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CAUTION
The clutch disk contains asbestos, which causes some forms of lung disease and may be a cancer causing agent. Do not clean the clutch or housing with compressed air. Use a damp rag to wipe off surfaces and throw away the rag. Use commercial available brake cleaners if a solvent is necessary. Avoid inhaling any dust from the clutch surfaces.


NOTE
The clutch disk, pressure plate, release bearing and pilot bearing are considered normal wear items. If the clutch disk or pressure plate are worn/defective, all of these components should be replaced.

Removal & Installation




NOTE
Inspect the rear main/flywheel seal for leakage when accessing the clutch.

  1. Remove the transmission as outlined in this section.
  2.  
  3. Place a suitable drain pan under the clutch assembly.
  4.  


CAUTION
Eye protection should be worn at all times. The use of a protective breathing mask is recommended. Use care, and do not allow exposed skin to come in contact with cleaning solvents or clutch dust.

  1. Clean the clutch assembly with an approved brake cleaning fluid.
  2.  
  3. Lock the flywheel in place using a suitable flywheel locking tool.
  4.  
  5. Insert, if available, a clutch alignment tool.
  6.  
  7. Matchmark the pressure plate to the flywheel.
  8.  
  9. Remove the clutch pressure plate fasteners evenly using a crisscross pattern, then remove the clutch pressure plate. If a clutch alignment tool is not being used, remove the pressure plate slowly to prevent the clutch disk from suddenly falling out of place. Make note of the clutch plate installation direction before removing to ensure proper reassembly. Some clutch disks can be installed backwards, however in doing so, will not allow adequate movement of the pressure plate fingers. If installed in this fashion, the clutch will not disengage!
  10.  
  11. Check the clutch driven disc for excessive wear or cracks. If the clutch disk's hub has integral torsional dampening springs, as used with standard one piece flywheels, check the springs for breakage and a tight fit. Replace the disk if the springs are loose, broken, or cracked. Dual mass flywheels use a clutch disk with a solid hub and do not use damper springs, however both types of clutch disks should be inspected for spline wear and the rivets inspected for tightness. Replace the disk if the rivets are loose, if the splines are worn excessively, or if the inner hub shows signs of fatigue, cracking or looseness.
  12.  

Clutch disk lining wear limit as measured from the head of the rivet to the lining surface:



Minimum thickness: 0.04 inches (1.0mm)
 

  1. Check the flywheel and pressure plate to make sure they are not scored, cracked, or burned, even at a small spot. Use a straight edge and a feeler gauge to make sure the contact surface is true. Replace any defective parts. Signs of bluing on the pressure plate or flywheel are indicators of excessive heat, usually caused by excessive clutch slippage. If bluing has occurred on the pressure plate it must be replaced as the spring's clamping force has been compromised and even with a new clutch disk installed, clutch plate slippage and/or premature failure is likely to occur.
  2.  



Click image to see an enlarged view

Fig. A pressure plate can be checked for flatness using a precision straight edge and a 0.004 inch (0.10mm) feeler gauge



Click image to see an enlarged view

Fig. A clutch disk alignment tool shown installed through the clutch hub. Note the similarity of the alignment tool and . . .



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Fig. . . . the transmission input shaft



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Fig. The clutch disk must be installed properly to ensure proper operation. Some disks are stamped on the inner hub to denote the direction of installation



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Fig. The clutch disk is checked for wear by measuring the distance from the head of the rivet to the surface lining. The disk should be replaced if the distance is 0.040 inches (1.0mm) or less



Click image to see an enlarged view

Fig. The clutch fork retaining clip shown installed on the fork's pivot with the fork removed



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Fig. The clutch release fork is held in place by a small wire retaining clip. The release bearing slides onto the guide tube and into the fork



Click image to see an enlarged view

Fig. The clutch alignment tool shown holding the disk in place with the pressure plate removed



Click image to see an enlarged view

Fig. With the alignment tool installed, torque the fasteners using a crisscross pattern. A click-type torque wrench works well in this application

To install:


NOTE
When replacing the clutch disk, the pressure plate and release bearing should also be replaced. Sometimes these components can be purchased as a clutch kit, with a substantial cost savings.


WARNING
Avoid using rebuilt or resurfaced clutch components on BMW vehicles. The tolerances of these components are critical to their operation and longevity.

  1. Clean as necessary and inspect the following items before reassembling the clutch. Replace worn or damaged components as necessary:

    Clutch lining wear
     
    Flywheel surface condition
     
    Rear main/flywheel oil seal
     
    Transmission input shaft seal
     
    Clutch pressure plate surface condition
     
    Flywheel starter ring gear tooth damage
     
    Clutch fork, check for cracks or excessive wear
     
    Clutch pilot bearing, check for binding and looseness
     
    Clutch hub wear, and if used, damper spring condition
     
    Clutch release bearing, check for binding and looseness
     
    Clutch pressure plate mounting fasteners, replace on S50 engines
     
    Dual mass flywheels, inspect the viscous coupling as outlined in this section.
     

  2.  


NOTE
On S50 engines, the pressure plate mounting bolts must be replaced.


WARNING
The clutch pressure plate mounting fasteners must be a matched set otherwise the engine's balance may be upset. If one fastener is damaged or lost, replace all the fasteners as a set. If the flywheel is removed, the flywheel fasteners must be replaced.


NOTE
On S14 engines, the pressure plate mounting bolts and taper sleeve must be replaced.

  1. Make sure the friction surfaces of the clutch, flywheel and pressure plate are clean and dry. If the flywheel, or pressure plate are to be replaced, make sure the protective coatings are properly removed as recommended by the manufacturer. Often times these components are packaged and wrapped with an oiled cloth and/or a protective coating to prevent rusting during shipping and storage.
  2.  
  3. Install a clutch alignment tool through the splines of the clutch disk and place the disk against the flywheel, then slide the alignment tool into the pilot bearing to hold the disk in place. Make sure the disk is installed in the correct direction.
  4.  


WARNING
A clutch alignment tool should be used when assembling the clutch. Proper alignment of the clutch splines and the pilot bearing is critical for the input shaft of the transmission to slide into position without binding or damage.

  1. If the flywheel was removed or replaced, make sure it is installed properly, and if equipped, the speed and reference mark sensors are properly installed.
  2.  


WARNING
If the vehicle is equipped with a flywheel that uses speed and reference sensors, make sure they are properly installed and not damaged, otherwise the engine management system may not function upon reassembly.

  1. Install a flywheel locking tool to prevent the flywheel from rotating.
  2.  
  3. Place the pressure plate against the clutch disk and flywheel, making sure the mounting holes are properly aligned.
  4.  
  5. Initially install the fasteners by hand turning them at least four complete revolutions in a crisscross pattern. On S50 engines, the pressure plate mounting bolts must be replaced. On S14 engines, the pressure plate mounting bolts and taper sleeve must be replaced.
  6.  
  7. Continue tightening the fasteners evenly in a crisscross pattern while holding the clutch alignment tool centered. Even with an alignment tool installed, the free-play in the release bearing and the weight of the clutch disk is enough to allow a slight amount of misalignment.
  8.  
  9. Once the fasteners begin to apply tension to the pressure plate, slide the clutch alignment tool in and out to check for excessive drag. If excessive drag is felt the clutch disk is not uniformly aligned and it must be moved slightly until the tool can be removed and installed easily. If necessary, back the clutch pressure plate fasteners off to relieve the tension so the clutch disk can be moved slightly.
  10.  
  11. Torque the fasteners in a crisscross pattern as follows:

    M8 8.8: 18 ft. lbs. (24 Nm)
     
    M8 10.9: 25 ft. lbs. (34 Nm)
     
    S14 M8 10.9: 25 ft. lbs. (34 Nm)
     

  12.  
  13. Slide the clutch alignment tool in and out to recheck for excessive drag and correct as necessary.
  14.  
  15. Coat the following with a light coating of an approved high temperature grease.

    The transmission input shaft splines
     
    Release bearing-to-fork contact area
     
    Release fork pivot and slave cylinder actuation rod contact area
     
    Release bearing interior collar and sliding sleeve (Do not grease these if the collar is plastic, clean only before assembly)
     

  16.  
  17. Install the release fork onto the transmission, making sure the retaining clip is properly fastened onto the grooved shaft of pivot ball, and clamped around the release fork.
  18.  
  19. Slide the release bearing onto the guide tube and center it in the release fork.
  20.  
  21. The balance of assembly is in reverse order of removal, noting the following:
  22.  
  23. Keep the mating surfaces of the transmission and engine parallel with one another as the transmission is installed.
  24.  
  25. If necessary, put the transmission in gear and move the output drive flange until the transmission input shaft aligns with the clutch hub.
  26.  
  27. Check and top off all fluid levels as necessary.
  28.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heat shield, then the mounting bolts
     
    Speed and reference mark sensors at the flywheel housing. Mark the plugs for reinstallation.
     
    Transmission and clutch housing
     
    With a 265/6 transmission (without an integral clutch housing), clutch housing. On vehicles with 6-cylinder engines, a Torx® socket is required.
     

  4.  
  5. Prevent the flywheel from turning, using a suitable locking tool.
  6.  
  7. Loosen the mounting bolts one after another gradually, 1-112
  8.  
  9. Remove the mounting bolts, clutch and driveplate. Coat the splines of the transmission input shaft with Molykote® Long-term 2, Microlube® GL 2611. Be sure the clutch pilot bearing, located in the center of the crankshaft, turns easily.
  10.  
  11. Check the clutch driven disc for excess wear or cracks. Check the integral torsional damping springs, used with lighter flywheels only, for tight fit. Inspect the rivets to be sure they are all tight. Inspect the flywheel to be sure it is not scored, cracked, or burned. Use a straightedge to verify the contact surface is true. Replace any defective parts.
  12.  


    Click image to see an enlarged view

    Fig. Clutch pressure plate mounting bolts


To install:


NOTE
On vehicles with 6-cylinder engines, the clutch pressure plate must fit over dowel pins.

  1. To install, fit the new clutch disk on a suitable clutch alignment tool and center the tool with the flywheel by centering it with the clutch pilot bearing. Mount the clutch pressure plate and install the mounting bolts. Clutch mounting bolts: 16-19 ft. lbs. (21-26 Nm).
  2.  
  3. When installing the clutch retaining bolts turn them in gradually to evenly tighten the clutch pressure plate to prevent warpage.
  4.  
  5. Install or connect the following:

    Clutch housing, if equipped with separate housing, then the transmission. If the clutch housing is part of the transmission, install the transmission.
     
    Speed and reference mark sensors, if equipped; then the heat shield
     
    The remaining components in the reverse order from which they were removed
     
    All remaining fluids as necessary
     
    Negative battery cable
     

  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heat shield, then the mounting bolts. Disconnect the speed and reference mark sensors at the flywheel housing. Mark the plugs for reinstallation.
     
    Transmission and clutch housing
     
    With a 265/6 transmission (without an integral clutch housing), clutch housing. On vehicles with 6-cylinder engines, a Torx® socket is required.
     

  4.  
  5. Prevent the flywheel from turning, using a suitable locking tool.
  6.  
  7. Loosen the mounting bolts one after another gradually, 1-1 1 / 2 turns at a time, to relieve tension from the clutch.
  8.  
  9. Remove the mounting bolts, clutch and driveplate. Coat the splines of the transmission input shaft with Molykote® Long-term 2, Microlube® GL 2611. Be sure the clutch pilot bearing, located in the center of the crankshaft, turns easily.
  10.  
  11. Check the clutch driven disc for excess wear or cracks. Check the integral torsional damping springs, used with lighter flywheels only, for tight fit. Inspect the rivets to be sure they are all tight. Inspect the flywheel to be sure it is not scored, cracked, or burned. Use a straightedge to verify the contact surface is true. Replace any defective parts.
  12.  

To install:


NOTE
On vehicles with 6-cylinder engines, the clutch pressure plate must fit over dowel pins.

  1. To install, fit the new clutch disk on a suitable clutch alignment tool and center the tool with the flywheel by centering it with the clutch pilot bearing. Mount the clutch pressure plate and install the mounting bolts. Clutch mounting bolts: 16-19 ft. lbs. (21-26 Nm).
  2.  
  3. When installing the clutch retaining bolts turn them in gradually to evenly tighten the clutch pressure plate to prevent warpage.
  4.  
  5. Install or connect the following:

    Clutch housing, if equipped with separate housing, then the transmission. If the clutch housing is part of the transmission, install the transmission.
     
    If equipped, speed and reference mark sensors, then the heat shield
     
    The remaining components in the reverse order from which they were removed
     
    All remaining fluids as necessary
     
    Negative battery cable
     

  6.  

  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.
  2.  
  3. Remove the transmission and clutch housing.
  4.  
  5. On vehicles with 6-cylinder engines, a Torx® socket is required. If equipped with a 265/6 transmission (without an integral clutch housing), remove the clutch housing.
  6.  
  7. Prevent the flywheel from turning, using a locking tool.
  8.  
  9. Loosen the mounting bolts one after another gradually, 1-1 1 / 2 turns at a time, to relieve tension from the clutch.
  10.  
  11. Remove the mounting bolts, clutch and driveplate. Coat the splines of the transmission input shaft with Molykote® Long-term 2, Microlube® GL 2611 or equivalent. Make sure the clutch pilot bearing, located in the center of the crankshaft, turns easily.
  12.  
  13. Check the clutch driven disc for excess wear or cracks. Check the integral torsional damping springs, used with lighter flywheels only, for tight fit. 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 straightedge to make sure the contact surface is true. Replace any defective parts.
  14.  

To install:

  1. To install, fit the new clutch plate and disc in place and install the mounting bolts.
  2.  
  3. When installing the clutch retaining bolts turn them in gradually to evenly tighten the clutch disc and to prevent warpage.
  4.  
  5. Install the transmission and the clutch housing.
  6.  
  7. If equipped, install the speed and reference mark sensors. Install the heat shield.
  8.  
  9. Note that on vehicles with 6-cylinder engines, the clutch pressure plate must fit over dowel pins. Torque the clutch mounting bolts to 16-19 ft. lbs. (21-26 Nm).
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heat shield, then the mounting bolts
     
    Speed and reference mark sensors at the flywheel housing. Mark the plugs for reinstallation.
     
    Transmission and clutch housing
     
    With a 265/6 transmission (without an integral clutch housing), clutch housing. On vehicles with 6-cylinder engines, a Torx® socket is required.
     

  4.  
  5. Prevent the flywheel from turning, using a suitable locking tool.
  6.  
  7. Loosen the mounting bolts one after another gradually, 1-1 1 / 2 turns at a time, to relieve tension from the clutch.
  8.  
  9. Remove the mounting bolts, clutch and driveplate. Coat the splines of the transmission input shaft with Molykote® Long-term 2, Microlube® GL 2611. Be sure the clutch pilot bearing, located in the center of the crankshaft, turns easily.
  10.  
  11. Check the clutch driven disc for excess wear or cracks. Check the integral torsional damping springs, used with lighter flywheels only, for tight fit. Inspect the rivets to be sure they are all tight. Inspect the flywheel to be sure it is not scored, cracked, or burned. Use a straightedge to verify the contact surface is true. Replace any defective parts.

    Click image to see an enlarged view

    Fig. Clutch pressure plate mounting bolts

  12.  

To install:


NOTE
On vehicles with 6-cylinder engines, the clutch pressure plate must fit over dowel pins.

  1. To install, fit the new clutch disk on a suitable clutch alignment tool and center the tool with the flywheel by centering it with the clutch pilot bearing. Mount the clutch pressure plate and install the mounting bolts. Clutch mounting bolts: 16-19 ft. lbs. (21-26 Nm).
  2.  
  3. When installing the clutch retaining bolts turn them in gradually to evenly tighten the clutch pressure plate to prevent warpage.
  4.  
  5. Install or connect the following:

    Clutch housing, if equipped with separate housing, then the transmission. If the clutch housing is part of the transmission, install the transmission.
     
    Speed and reference mark sensors, if equipped; then the heat shield
     
    The remaining components in the reverse order from which they were removed
     
    All remaining fluids as necessary
     
    Negative battery cable
     

  6.  

 
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