Removal, inspection and installation of clutch components (BMW 5 Series E28)

Removal

Access to the clutch is usually provided by removing the transmission, without removing the engine from the vehicle. If the engine must be removed for a major overhaul, take the opportunity to inspect the clutch for signs of wear, replacing worn components as necessary. The procedure below assumes that the engine is in the vehicle.

1. Remove the transmission from the vehicle using the recommendations in Chapter Manual transmission (MT).



2. To support the clutch disc during removal, insert a clutch centering tool or old transmission input shaft into the center of the clutch pressure plate.



3. Carefully inspect the flywheel and pressure plate for alignment marks. If there are none, apply them with a scraper or paint so that the pressure plate and flywheel are installed in the same position relative to each other when assembled.





4. Loosen the bolts securing the pressure plate to the flywheel (indicated by arrows), turning each one a little at a time, doing this diagonally until all the spring pressure is released.

5. Grasp the pressure plate and loosen the bolts completely, then separate the pressure plate and driven disc from the flywheel. Pay attention to which way the clutch disc is screwed.

Inspection

Typically, when problems occur with clutch operation, they can be attributed to wear of the clutch disc assembly. However, other components should be checked at the same time.

1. Inspect the flywheel (see Part Repair work carried out without removing the engine from the vehicle).



2. Check the pilot bearing at the end of the crankshaft. Make sure it rotates smoothly and quietly.



3. If the contact surface of the bearing with the transmission input shaft is damaged or worn, replace the bearing.

4. Using a puller, remove the guide bearing.



5. Install the new bearing using the replacement head and hammer.



6. Inspect the clutch disc lining.





7. Check for signs of oil contamination and general wear. If the lining is dirty or worn, replace the disc. Also check the runout and thickness of the clutch disc, then compare the results with the values given in the Size and Adjustment Data Table at the end of the Manual. If the disc is too thin or warped, replace it. Check for loose rivets, warping, cracks, broken springs or other obvious damage. As stated above, the clutch disc is usually replaced every time it is removed, so if there is any doubt about its condition, it is best to replace it.



8. The release bearing (1) is usually replaced at the same time as the clutch disc. Remove the bearing from the input shaft.

9. It is also recommended to release the return spring (3), remove the release lever (2) and inspect the recess for the tip of the slave cylinder pusher. Install the clutch release lever and bearing in the reverse order.

10. Check the working surface of the pressure plate. If it has cracks, grooves, scratches, oil or discolored spots from overheating, or other damage, the plate should be replaced. Apply a flatness gauge to the surface and make sure it is flat.





11. Check for loose rivets or deformed spring petals.

12. If there is any sign of wear on the pressure plate, replace it. It is recommended to make it a rule to replace all components of the clutch assembly (driven disc, pressure plate and release bearing), or if the old components have been in service for a long time.

Installation

1. Before installation, thoroughly clean the working surfaces of the flywheel and pressure plate. Handle these components only with clean hands. Do not allow oil or dirt to come into contact with the friction surfaces of the clutch components.

2. Place the driven and pressure plates on the flywheel, holding the driven plate in place with a clutch alignment tool. Make sure the driven plate is installed correctly (new plates are usually marked "Flywheel side" - the side facing the flywheel - or something similar). When installing the old pressure plate, make sure that the alignment marks applied earlier match.

3. Tighten the pressure plate to flywheel mounting bolts using your fingers only, working in a circular motion.

4. If not already done, install the clutch alignment tool into the center of the clutch basket (see illustration). Move the disc so that the tool is perfectly centered and the transmission input shaft easily enters the disc into the pilot bearing. If the disc is not centered correctly, it will be impossible to install the transmission.



5. Tighten the bolts securing the pressure plate to the flywheel, little by little, one at a time, moving diagonally to avoid deformation of the pressure plate, with the required force.

6. Lubricate the entire inside surface of the release bearing with high-temperature grease. Make sure that the inside of the oil groove is filled. Apply grease to the ball seat and the fork pins as well.

7. Install the transmission, slave cylinder and all previously removed components.

(Information obtained from this online resource BMWMAN)