1999 BMW 525i Workshop Manual

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Clutch
Clutch, installing (used SAC components)
When reinstalling a previously used self-adjusting clutch
(SAC), special tools are needed to reset the self-adjusting
ring to its original position.
CAUTIOI\C
Avoidcontaminating clutch friction suifaces with oilorgrease.
Do not touch these
suifaces.
- Place SAC pressure plate on clean worlc suriace.
4 Place BMW special tool 21 2 180 on pressure plate
Note that locating hoolts of special tool engage pressure
plate adjusting ring openings
(inset).
Grip tool firmly and squeeze special tool handles together.
Tighten down special tool knurled screws (arrows).
- SAC adjustment ring is now in its original position.
4 Install BMW special tool 21 2 170 on SAC pressure plate.
Fit fingers of special tool in slots above dowel pin bores.
Tighten down knurled nut (arrow) finger-tight.
Screw in T-handle until pressure plate diaphragm spring is
pretensioned to stop.
< Center clutch disc on flywheel using centering tool.
5-speed transmission: Special tool 21 2 142
6-speed transmission: Special tool 21 2 141
G6S-3762 transmission: Special tool 21 2 201
CAUTION--
Be sure clutch disc is lacing the correct way The disc should
be
marked 'kngine side" or 'Transmission side':
NOTE-
The large bolt in the clutch disc centering tool is used to in-
stalland remove the tool only Once the disc is in place on tlie
flywheel, remove the bolt to male room for the SACpressure
plate.

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1 Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- lnstall SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques
Clutch to flywheel
- M8 (8.8 grade)
M8 (10.9 grade) 24
Nm (18
ft-ib)
34
Nm (25 ft-lb)
- Slip out clutch centering tool using large bolt.
- Remove flywheel locking tool.
Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CA U TIOG
Do not grease guide sleeve. If guide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- Install transmission. See 230 Manual Transmission
Tightening torques
Transmission to engine
- ME (Torx)
. M1O (Torx)
. M12 (Torx) 22
Nm (16 ft-lb)
43
Nm (32 ft-lb)
72
Nm (53 it-lb)

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Self-adjusting clutch (SAC), breaking in
With normal driving, 800 to 1000 gearshifts are required to
break in the clutch.
Break in the SAC gradually, with light to medium loads, to en-
sure correct operation and long life. Fast sports driving ma-
neuvers may destroy a new
clutch.The following break-in
procedure helps to create the correct coefficient of friction.
Drive normally on level grade. Starting speeds on level
grade may be up to 2000 rpm.
Upshift and downshift through all the gears at 3500
- 4000
rpm.
On medium grades (approx. 12% and up), start
off at ap-
prox. 2500 rpm for the first 5 or so times.
Tightening torques
Clutch slave cylinder to transmission case 22 Nm (16 It-lb)
Clutch master cylinder to pedal cluster 10 Nm (89 in-lb)
Bralte fluid line to clutch master or slave cylinder 17 Nm (13 ft-lb)
Transmission to engine
M8 (Torx) 22 Nm (16 fl-lb)
. M1O (Torx) 43 Nm (32 ft-lb)
MI2 (Torx) 72 Nm (53 it-lb)
Flywheel to crankshaft
6 cylinder engine (use new self-loclting bolts) 105 Nm (77 ft-lb)
V-8 engine 105 Nm (77 ft-lb)
Clutch to flywheel
M8 (8.8 grade)
M8 (10.9 grade) 24
Nm
(18 ft-lb)
34 Nm (25 ft-lb)

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230 Manual Transmission
General ........................... .23 0.2 Output shaft
seal. replacing (5-speed
.... Special tools ........................ .23 0.2 transmission) (transmission installed) 230-10
Manual transmission aoolications ....... .23 0.5 Output shaft seal. replacing (6-speed . . .... transmission) (transmission installed) 230-12 ........ Transmission Fluid Service .23 0.6 put shaft seal. replacing
Transmission fluid level. checking ....... .23 0.6 (transmission ............... 230-15
........... Transmission fluid, replacing .23 0.6
Transmission Removal ................... ..... Transmission External Service .23 0-7 and installation 230-1
Back-up light switch, replacing .......... .23 0-' Transmission, removing and installing 230-16 ...
Selector shaft seal. reolacina .
(transmission installed) ................ .23 0.8

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230-2
I Manual Transmission
This repair group covers external transmission service, including removal and installation of the transmission unit.
Internal transmission repair is not covered. Special tools and
procedures are required to disassemble and
service the
internal geartrain.
Special tools
BMW specified tools are required for removal and installation
of the manual transmission, as well as the removal and instal-
lation of seals at the transmission input, output, and selector
shafts. If these tools are unavailable, equivalent tools may be
substituted.
4 Transmission jack
(Tool No, BMW 00 2 030)
4 Seal puller
(Tool No. BMW 00
5 01 0)
4 Engine support block (V-8 models)
(Tool No. BMW
11 7 31 0)
4 Engine support bloclc (6 cylinder models)
(Tool No.
BMW 11 7 370)

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I Manual ~ransmissionl
4 Transmission flange counterhold tool
(Tool No. BMW 23 0 020)
4 Transmission support (for use with transmission jack)
(Tool No. BMW 23
0 040)
Selector seal extractor
(Tool No. BMW 23
0 210)
4 Selector seal installation drifl
(Tool No. BMW 23
0 220)
4 Input shaft seal puller (slide hammer)
(Tool No. BMW 23
0 490)
4 Output shaft flange nut socltet (27 mm)
(Tool No. 23
1 210)
4 Output seal installation drift
(Tool No.
BMW 23 2 300)
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230-4
/Manual Transmission
4 Output shaft flange nut socket (36 mm)
(Tool No. BMW 23 2 320)
Seal installation drift
(Tool No. BMW 23 2
340,23 2 430,24 0 11 0)
4 Output shaft seal installation drift
(6-speed transmission) (Tool No. BMW 23 2 480)
4 Input shaft seal installation tools (6-speed transmission)
(Tool No. BMW 23 2 490 (23 2 491 and 23 2 492))
< Output flange installation tool
(6-speed transmission) (Tool No. BMW 23 3 01 0)