Clutch and Flywheel Replacement DIY | BMW E39 540i

Today I’m replacing the clutch on my 2000 BMW E39 540i fitted with the 6-speed manual transmission, and I'm showing you everything you need to know so you can replace the clutch on your E39 yourself. I've also included important information about removing the E39's flywheel if you're planning on replacing that as well. This is a challenging and time consuming DIY project that requires a lot of disassembly, but it's certainly not impossible as long as you have the space and proper tools (listed below).
TIME STAMPS:
Exhaust & Heat Shields - 0:21
Driveshaft - 01:44
Transmission Bell Housing - 02:43
Clutch & Pressure Plate - 05:40
Flywheel - 06:16
Torque Values - 07:41
DIY Summary - 09:59
PROCEDURE:
This procedure is for a BMW E39 540 fitted with the M62 V8 engine and 6-speed manual transmission. Overall, this is an involved repair that will most likely take around 8 hours to complete, but I'd recommend allocating an entire weekend so you don't rush. Parts ran me about $270, including the clutch kit and gasket that seals the CV joint and differential flange. BE CAREFUL WHEN REMOVING THE SLAVE CYLINDER AS THE RUBBER BOOT CAN TEAR AND FORCE YOU TO REPLACE IT.
PARTS:
1. Luk Clutch Kit - www.fcpeuro.com/products/bmw-clutch-kit-e39-luk-21217528209
2. CV Joint Gasket - www.fcpeuro.com/products/bmw-cv-joint-gasket-26111229504
3. Flywheel - I didn't replace my flywheel, but I recommend shopping around at shops like FCP Euro, ECS Tuning, Pelican Parts, etc. to find the best quality for your budget.
TOOLS:
There are a couple special tools that you need to be aware of and I've marked them with a * below. I go into more detail in the video, but I've included links to some of your options.
Exhaust + Heat Shield Tools:
- 13mm Socket
- 10mm Socket
- 8mm Socket
Driveshaft Tools:
- 16mm Wrench
- 21mm Socket
- 21mm Wrench
- 13mm Socket
Bell Housing Tools:
- Transmission Jack
- E12 Socket* (~$10): www.harborfreight.com/14-in-38-in-drive-impact-e-socket-set-7-pc-67898.html?cid=paid_google|||67898&gclid=CjwKCAjwv4_1BRAhEiwAtMDLso20us7kBfMGAujfLdDXhQkJmnu-xg8Tt96bh1Kn-AyM6EmFugMbeBoCWekQAvD_BwE
- 16mm Wrench
- 13mm Socket
- 3+ ft of extensions
- Breaker Bar
- Swivel Joint (~$8): www.harborfreight.com/universal-joint-socket-adapter-set-3-pc-63141.html?cid=paid_google|||63141&gclid=CjwKCAjwv4_1BRAhEiwAtMDLstIIani1v_oATx2u8_ZWDjUJOVRxja2-G4kmEn1y1Mmvzcoa4cBvcRoCt9AQAvD_BwE
Clutch / Pressure Plate Tools:
- 6mm Hex Head Socket* (~$8): www.harborfreight.com/38-in-drive-metric-hex-socket-set-6-pc-69546.html?cid=paid_google|||69546&gclid=CjwKCAjw4pT1BRBUEiwAm5QuRw01VEVfZV0JzMy9gLNc4R_lTXigoBTkPs1zANVb_Y2r_NRKrjfTMxoChdUQAvD_BwE
Flywheel Tools:
- Special T60 Torx Socket* ($32) FCP Euro: www.fcpeuro.com/products/bmw-t60-flywheel-bolt-socket-cta-3759?ads_cmpid=1586640911&ads_adid=59893888775&ads_matchtype=&ads_network=g&ads_creative=298302526031&ads_targetid=pla-329388689743&ttv=2&gclid=Cj0KCQjwka_1BRCPARIsAMlUmErZ25UjgdwWuI0PBMLC9pCsAqsoBjumGFwxjZ2dClcEMqm0r9I-35EaAlcFEALw_wcB#fitment
- Breaker Bar
- Flywheel Locking Tool (or improvise)* (~$57): www.fcpeuro.com/products/bmw-bracket-no-119260-83300493938?ads_cmpid=1586640911&ads_adid=59893888775&ads_matchtype=&ads_network=g&ads_creative=298302526031&ads_targetid=pla-327620319311&ttv=2&gclid=Cj0KCQjwka_1BRCPARIsAMlUmErr83j6vIQicoiBZCVvVfGx1XbMFjEGxw0A73dSGXRJMLEQsF9j_4caAsjHEALw_wcB
Please leave a comment if you have any questions, thanks for watching!
Disclaimer:
Due to factors beyond the control of Tire Kickers, I cannot guarantee against improper use or unauthorized modifications of this information. Tire Kickers assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. Tire Kickers recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of Tire Kickers, no information contained in this video shall create any expressed or implied warranty or guarantee any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Tire Kickers.

[@TireKickers]

There are actually 9 T60 Torx bolts that secure the flywheel. I'm honestly not sure where I got 6, but everything else holds true. Let me know if you have any questions!

[@ashleyhopkins6296]

did you machine your flywheel or get a new one? are the flywheel bolts re-usable?

[@jeffreyjones5161]

I watched this video multiple times during the removal of my e39 transmission. Can't thank you enough for the easy to understand and follow walkthrough. This video is e39 gold!

[@cmkm54]

Just a tip for anybody else. It is way easier to access the top transmission bolts from under the hood behind the engine. Thats how I always do these v8 bmws. Fantastic video!!!

[@DoubleJThe]

I was told the same, remove the cabin air filter housings and the bolts are right there. I did it from underneath though, lots of extensions.

[@percyjackson2800]

Very nicely done! Not a very complicated job it just takes a bit of time and effort, especially if laying on your back.

[@TireKickers]

Appreciate it! Agreed, I tried to highlight the tricks that might make it a little easier but there really aren't any shortcuts. I can imagine doing this while on your back is a lot of fun lol.

[@KKE1978]

Thanks to you i just completed this job. Honestly its not that bad as long as you are patient. My hardest part was un bolting the exhaust they were really rusted. I finally let the soak in vinegar and next day it was easier to remove.

[@TireKickers]

Really glad to hear that! Funny you say that, I swear it's always the seemingly "easy" things that end up giving me the most trouble on these cars lol

[@adroitcaptor]

Also, not sure what it took other people, but I was out about 10hours (with a friends help). That was working off our backs, including getting the car in the air, food breaks, a good about of cleaning, etc. Not sure if it took other people that long but if this is your first time expect an all day deal. We dis not have special tools other than what is listed to get the job done, (just 1 floor jack). YOU NEED 2 PPL to get the trans back in safely IMO (WATCH THE O2 PLUGS!), unless you got some nice equipment maybe? lol good luck! With this video you can easily do the job, just takes time.

[@DoubleJThe]

My top 2 bolts have a smaller head on them. The E12 took them out, but mangled them and they'll need to be replaced. If you're doing this on your back, you'll also want to remove the crank position sensor instead of just unplugging it, it's expensive and your ring gear will catch on it and explode it all over the place.

[@abdulrehmanmohammad8047]

Thanks man you helped me so much

[@adroitcaptor]

This seriously helped me. TY

[@mchipman7879]

Great job on this video, it's exactly what I needed as I was just getting ready to start this job myself. How should I decide whether or not to replace my flywheel though?

[@TireKickers]

Glad you found it helpful! There are some common symptoms to look out for with a bad flywheel so I'll keep it general. I'd recommend that if you have a hunch that your flywheel is bad, it's prolly best to replace it while you're in there. Symptoms: 1. Gear Slippage 2. Burnt Smell 3. Clutch pedal vibrations 4. Clutch drag (clutch not releasing properly) 5. Clutch chatter

[@adroitcaptor]

Dual mass cannot be resurfaced properly. If you plan on having the car a while I say replace it. The other thing to think about, with shipping time etc., you may be waiting an additional week or two if you end up needing it. Do it right the first time IMO.

[@johnwoolfrey5093]

I just received my LUK clutch kit. It had the disc, SAC pressure plate, throw-out and pilot bearings. The PP did not come with the shipping plate but the PP was in its reset position. I also noticed your PP also did not have the shipping plate either (you didn't remove it after installing the PP). Were you concerned about no shipping plate as I am? I assume we can install the PP without the shipping plate. Thanks/John

[@ib1p]

how did ths work out for you ? I ordered a LUK clutch kit from fcp and received no locking plate also. Was it already preset or do i need to reset it?

[@johnwoolfrey5093]

@@ib1p My pressure plate was already reset from factory (the reset springs were compressed pretty much fully). When I installed I just torqued each bolt by 1/2 turn each in a criss-cross fashion until all pressure plate bolts were tight. Then I went around with the torque wrench and did the final tighten. After clutch install is done and tranny is back in, press the clutch pedal a couple times. I had no issues.

[@johnwoolfrey5093]

@@ib1p I later had to replace my dual mass flywheel. I removed my tranny and the new pressure-plate / clutch. At that time I reset the now used pressure plate and installed it as mentioned earlier with 1/4 to 1/2 turns per bolt. I pressed the clutch pedal a couple times after the install and before starting the car. No issues. I was told on a Facebook post that if you were just removing your pressure plate and then re-installing it with the same (used) clutch disk then you don't have to reset the pressure plate.

[@adambaros7958]

Great video but i have a question why do i need to replace the diff flange gasket

[@TireKickers]

Good question Adam, replacing the gasket is a best practice because odds are it’s old and won’t seal correctly if you try and use it again. I’ve had a diff gasket completely disintegrate when trying to remove it so I had no choice but to replace it.

[@oshogweikekhai5499]

Does reinstalling the flywheel need timing?

[@mrkijack]

Very helpful! Thanks

[@asfiraneabderaouf3528]

Hi! Is it the same procedure whit E39 530 d ?

[@INNO222]

Would the 6cyl e39 be any easier? Thanks

[@DougBe38]

no new pilot bearing?

[@lonerider5315]

Never show how to str move the pilot bearing 😞