June 2021

JUNE 2021 AFTERMARKET 37 Remove and replace Attention now turns to the gearbox and the clutch release system. Remove the release bearing and arm assembly, check the nylon pivot point and guide tube for wear (Fig.6) and replace if required. Then clean the bell housing using clutch and brake dust cleaner. Now fit the release bearing to the new release arm ensuring its position and location are correct using the information on the bulletin in the box, as these may have a short and long reach position. Apply a light smear of high melting point grease to the guide tube and fit the release bearing assembly. Also apply a light smear of high melting point grease to the gearbox input shaft splines, mount the new clutch plate onto the input shaft, this will confirm the fitment is correct and evenly distribute the grease. Remove the clutch plate and wipe off any excess grease. Now mount the new clutch onto the dual mass flywheel. The specified BMW process must be followed at this point as the new clutch has a transport locking plate installed, which can only be removed when the clutch is bolted up. So, first de-grease the flywheel face and clutch pressure plate face using clutch and brake dust cleaner. Then, using the correct size mandrel, insert it into the spigot bearing (Fig.7) and then mount the clutch plate onto the mandrel ensuring it is the correct way around, indicated by Gearbox side. Locate the clutch cover/pressure plate on the flywheel dowels and insert the six bolts, tighten in an even and sequential sequence, torqueing the bolts to the manufacturer’s specification (Fig.8). Remove the transport locking plate using the correct size Allen key and rotate in an anti-clockwise direction, then use an 8mm bolt to remove the mandrel (Fig.9). Re-fit and road test Before re-fitting the gearbox, ensure the engine to gearbox alignment dowels are installed in the engine and also note that some of the bell housing bolts are one-use aluminium applications and must be replaced. The gearbox is now ready to be reinstalled. Ensure all cables and ancillary items are clear and will not get trapped, ease the gearbox into position and align on the dowels. Once located onto the dowels, secure in position with a couple of easily accessible bell housing bolts. Final installation is then in reverse order of the removal. However, always carry out a full road test to ensure a successful repair. Information on Schaeffler products, fitting instructions, labour times and much more can be found on the REPXPERT workshop portal: www.repxpert.co.uk Fig 2 Fig 3 Fig 4 Fig 5 Above: Fig 6 Above: Fig 7 Fig 8 Fig 9