Removal and installation, clutch check (BMW 5 Series E34)

Removal

Remove the gearbox.

Gradually loosen the drive disk mounting bolts by 1-1½ turns each time until it is relieved.

Caution: If the bolts come loose immediately, the diaphragm spring may be defective.

To prevent the flywheel from turning when unscrewing the bolts, block the flywheel with a screwdriver or rod.

Finally, completely unscrew the bolts.

Remove the drive and driven disks.

Caution: Do not drop the drive and driven discs when removing them, as this may result in difficulty disengaging the clutch or the clutch jerking after installation.

Wipe the flywheel with a rag soaked in gasoline.

Examination

Check the drive disk for scratches and burnt areas.



Check the integrity of the diaphragm spring "arrow".



Check the spring connections of the drive disk and cover for cracks and the reliability of the rivet connections. Replace the clutch with damaged or unreliable rivet connections.





Check the working surface of the drive disk for cracks, burnt areas and wear. Drive disks that are bent inward up to 0.3 mm can still be installed. The check is performed using a ruler and a set of feeler gauges.

Check the flywheel for scratches and burnt areas.

Treat the drive disk and flywheel with very fine sandpaper.

Oily and mechanically damaged drive disks must be replaced.

Measure the thickness of the drive disk linings with a caliper. The minimum permissible thickness is 7.5 mm, otherwise the disk must be replaced. The drive disk is also replaced if there are burnouts.



Check the spring windows, torsion springs and hub for signs of wear. With a composite flywheel, the driven disk has a rigid structure without dampers. In this case, torsion dampers are installed in the flywheel.



Remove the release bearing from the front gearbox cover and inspect it.

The runout of the driven disk is checked in the workshop. Lateral runout should not exceed 0.5 mm.

Note: This check must be carried out when reinstalling the previous driven disc and there were previously difficulties in disengaging the clutch.

Check the ease of movement of the ball bearing in the crankshaft groove. If necessary, remove the bearing with a puller and replace it.

Installation

Before installing a new clutch, remove the anti-corrosion protective coating from it.



Insert the drive and driven disks into the flywheel. Place the drive clutch disk on the corresponding mounting pins. Center the driven disk in the drive disk. For centering, it is best to use a HAZET shaft or the primary shaft from an old gearbox.

When installing the previous drive disk, install it according to the marking. The marking should be facing the gearbox.

Screw in the drive disk mounting bolts.

Sequentially tighten the drive disk mounting bolts by one to one and a half turns. Then remove the centering shaft.

Note: When tightening the bolts, the drive disk must enter the flywheel evenly and freely. The tightening torque for class 8.8 fastening bolts (indicated on the head of the Bulgarians is 22-24 Nm, class 10.9 - 30-35 Nm, cylindrical bolts: 22-24 Nm.

Lightly lubricate the gearbox input shaft keyways with Molykote Long them 2. For a composite flywheel, lubricate the keyways with Microlube 261.

Install the gearbox.