Replacing the clutch plate on a BMW 535i is a complex task that requires mechanical knowledge, tools, and a safe working environment. click here for more details on the download manual…..
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Here’s a detailed description of the components involved and a step-by-step guide to perform the replacement.
### Tools and Equipment Needed
1. **Basic Hand Tools**:
– Socket set (including metric sockets)
– Combination wrenches
– Torque wrench
– Screwdrivers (flat and Phillips)
– Pliers
– Hammer
2. **Specialized Tools**:
– Clutch alignment tool
– Flywheel locking tool (specific to BMW models)
– Transmission jack or support for holding the transmission
– Brake cleaner or solvent
3. **Safety Equipment**:
– Safety glasses
– Gloves
– Mechanic’s mat or creeper
### Components Involved
1. **Clutch Plate**: The friction disc that engages and disengages the engine from the transmission.
2. **Pressure Plate**: The component that applies pressure to the clutch plate.
3. **Flywheel**: The rotating disk that the clutch plate presses against.
4. **Release Bearing**: The bearing that allows the clutch to engage/disengage.
5. **Clutch Fork**: The lever that operates the release bearing.
6. **Pilot Bearing**: The bearing that supports the end of the transmission input shaft.
7. **Transmission**: The component that houses the gears and connects to the engine.
8. **Flywheel Bolts**: Bolts that secure the flywheel to the engine crankshaft.
9. **Pressure Plate Bolts**: Bolts that secure the pressure plate to the flywheel.
### Step-by-Step Guide to Replace Clutch Plate
#### Preparation
1. **Disconnect the Battery**: Remove the negative terminal to prevent any electrical shorts.
2. **Lift the Vehicle**: Use a jack to raise the car and secure it with jack stands.
3. **Remove Underbody Panels**: If applicable, remove any panels obstructing access to the transmission.
#### Removal of the Transmission
1. **Remove the Driveshaft**:
– Unbolt the universal joint from the differential and transmission.
– Slide the driveshaft out of the transmission.
2. **Disconnect the Transmission**:
– Unplug any electrical connectors (reverse light switch, etc.).
– Remove the transmission mount bolts and support the transmission with a jack.
– Remove the bellhousing bolts securing the transmission to the engine.
3. **Separate the Transmission**:
– Carefully slide the transmission away from the engine. Use the transmission jack for support.
#### Clutch Assembly Removal
1. **Remove the Pressure Plate**:
– Remove the bolts securing the pressure plate to the flywheel using a socket and ratchet.
– Gently pull the pressure plate away from the flywheel.
2. **Remove the Clutch Plate**:
– Once the pressure plate is removed, slide the clutch plate off the flywheel.
3. **Inspect the Flywheel**:
– Check the flywheel surface for any damage or wear. If it’s scorched or warped, it may need resurfacing or replacement.
– If applicable, replace the pilot bearing in the flywheel.
#### Installation of New Components
1. **Install the New Clutch Plate**:
– Align the new clutch plate onto the flywheel. Use a clutch alignment tool to ensure proper alignment.
2. **Install the Pressure Plate**:
– Position the pressure plate over the clutch plate and align it with the holes on the flywheel.
– Hand-tighten the pressure plate bolts in a star pattern to ensure even pressure.
– Torque the pressure plate bolts to the manufacturer’s specified torque.
3. **Install the Release Bearing**:
– Slide the new release bearing onto the clutch fork.
#### Reassembly
1. **Reattach the Transmission**:
– Carefully slide the transmission back into place, ensuring the input shaft engages with the clutch plate.
– Reinstall the bellhousing bolts
and torque them to the specified value.
– Reconnect any electrical connectors.
2. **Reinstall the Driveshaft**:
– Slide the driveshaft back into the transmission and secure it with bolts.
3. **Reconnect the Transmission Mount**:
– Secure the transmission mount to the chassis.
4. **Reinstall Underbody Panels**: If removed, put back any underbody panels.
#### Final Steps
1. **Reconnect the Battery**: Reattach the negative terminal.
2. **Check Clutch Fluid**: Ensure the clutch fluid reservoir is filled to the correct level if your vehicle has a hydraulic clutch system.
3. **Test the Clutch**: Before taking the vehicle for a drive, press the clutch pedal several times to ensure proper engagement and disengagement.
4. **Lower the Vehicle**: Remove the jack stands and lower the vehicle to the ground.
### Conclusion
Replacing the clutch plate on a BMW 535i requires patience and attention to detail. Ensure that each bolt is torqued to the specifications provided by the manufacturer and check all components for wear before reassembly. If you’re unsure at any step, consulting a repair manual specific to your vehicle or seeking professional assistance is advisable.
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