Replacing a BMW Self-adjusting Clutch & Dual-mass Flywheel Part 1 of 2

www.bavauto.com -- In this How-To DIY video series (Part-1 and Part-2) we will be replacing a typical BMW clutch and flywheel. For more details on this DIY, see our Tech Blog at www.blog.bavauto.com/go/clutchrepair . These videos show the full removal, replacement and reassembly of the self-adjusting clutch (SAC) and dual-mass flywheel, special instructions that MUST be followed in the installation of the self-adjusting clutch, failure modes of the dual-mass flywheel and finally, installation of the UUC lightweight flywheel and performance clutch. We will also install the UUC Short Shift Kit and DSSR. See the separate DIY video for the shifter install at www.blog.bavauto.com/go/shortshift . All of the parts shown in this DIY series are available at Bavarian Autosport. Visit our online store at www.bavauto.com or call or knowledgeable agents at 800-535-2002.
Don't forget to "like" this video and send us some comments!

[@bavarianautosport]

Thanks for the encouraging words. We certainly do want to help our customers with their BMW ownership and we are, indeed, enthusiasts ourselves.

[@GeorgeAusters]

This looks fun to do whilst lying on the floor of your driveway

[@bavarianautosport]

We do cover the complete process for clutch replacement in this two part video. If you have further questions, please feel free to give us a call at 800-535-2002.

[@goma3]

I never heard of your website before, but I am definitely buying some parts from you guys. If you put this much effort into DIY videos, that means you really care about your business and your customers. This is not just slap-on job, these are very carefully produced videos. Great customer service means a lot to me and you guys certainly deliver.

[@RBZ06LT6]

Nah it means they want the bands

[@Hubjeep]

Thanks for the video. The clutch started slipping on my 1998 M-roadster (S52) last week, car has 83K miles. This video was a nice refresher for me, it's been a few years since I have replaced a clutch. I forgot about the pivot pin and exhaust gaskets!

[@john2000cash]

Thank you for this informative video. I wish more local motor technicians have the courage to advise their customers to replace with the single mass flywheel. Personally I find the irony in the replacement of the DMF with a solid flywheel and non-adjusting clutch kit as too much to take...!

[@baltod4978]

THANK YOU!!! SO VERY MUCH! I'll be doing this in a month or two!

[@cockyhotty]

Very, very precise work! Well done!

[@adrianovergara2942]

well narrated and well explained very clear I have learned a lot from this video

[@Juleps007]

Sie sind ein sehr guter Lehrer, danke für ihr Video, ich konnte viel lernen! 🤗

[@farerse]

this looks professionaly done!

[@sonnym9905]

Fantastic video. Thank you very much.

[@diakoahar]

it's just a amazing and simple video! thanks for uploading :)

[@alexronn6400]

I love you for making this video.

[@liviudaniel5082]

great job ,video,big appreciation and like!thanks for share!

[@BY-ib9ew]

excellent video as usual

[@bavarianautosport]

Yes ... the only differnce on the SMG is the automated clutching and shifting. The transmission is basically the same as the standard transmission.

[@bavarianautosport]

Yes, the disc is marked as to which side goes toward the engine or transmission.

[@Passionate747]

Excellent videos well explained thanks for posting them the videos are a great help.

[@davidniquot6423]

A small lateral (Push-Pull left and right) play is normal and even exist on a new dual mass flywheel.

[@bavarianautosport]

On the BMW applications, we have found the conversions to be very smooth and solid, when installing the heavy conversion flywheel kits. the lightweight conversions, using the aluminum flywheels, have a bit less damping due to the lower rotational mass.

[@bavarianautosport]

Yes, the overall procedure would be similar to what we show. Some details will differ, but you certainly could use the videos for basic instruction. the Bentley repair manual would give you specific details. We have them at bavauto.com.

[@normansabel1850]

Leave 1 bolt to hold the flywheel while you pry it off the crankshaft. Easier than playing catch with a big piece of steel.

[@danielbailey848]

Great video! I am doing the clutch assembly on my 2002 325ci and I was wondering if I needed to support the engine while removing the transmission. I see that your engine appears to just be moving freely. Thanks for your help!

[@carslover3509]

great work

[@ilkinhamidov]

Thank you very much. Actually the issue was re manufactured clutch back up wheel. Took it out and it had a crack on through the body Under rev it would create dis balance and eventually would destroy the crankshaft bearings

[@colinanelay5505]

Very useful and wee presented. Thanks.

[@bavarianautosport]

In general, yes, your procedures will be very similar.

[@carmengonzalez3018]

THE BEST VIDEO EVER IN YOU TUBEI.

[@RogerMasson]

One minor, but incredibly important detail when removing the transmission is to make sure you have REMOVED the speed sensor, also known as the crankshaft position sensor, also known as the pulse generator. I missed this step on my 2003 M5 and it cost me at least a half hour trying to wrestle the transmission from the engine, and it also cost me the sensor. I don't know if this sensor is present in all E39's, but it is definitely there in the M5.

[@andreicamp]

Thanks for this awesome video! I do have one question though. Do you need to support the engine in any way? I believe the E39, like my E36, has 2 mounts for the engine, and 2 for the gearbox. I just remember when I replaced the driveshaft I had to use a jack to support the gearbox. Thanks again!

[@bavarianautosport]

If the flywheel has play, as the one in the video did, you will find that the vehicle has a jerky feeling when starting out and when changing throttle application. This vehicle also had a surging feeling when driving at a constant speed, due to the flywheel surface bouncing back and forth at light loading.

[@raulnyquist]

2:45 STARTS THE REAL DEAL!!!

[@bavarianautosport]

tonycstech - The clutch disc should say either; engine side or transmission side, on one of the sides, someplace on the metal hub area. If you are using a German clutch, such as Sachs, this may be in German.

[@bavarianautosport]

In a general sense, yes it does. Your details will be a bit different, but the overall procedures will be quite similar.

[@8NAYEEM]

good work

[@bavarianautosport]

Without driving the car, it's tough to make an accurate diagnosis. However, it does sound like the noise is coming from within the transmission, from your description. What fluid are you running in the transmission? Have you tried the RedLine MTL? See it on our site at bavauto.com . Another thought would be to try the Red Line 75w-90 fluid (it is OK to run this) to see if this changes the noise at all. If it does, you know that it is from within the transmission.

[@jtdouglas9535]

amazing quality. This is the equivalent of a shop class on BMWs with incredibly succinct detail. Thank you. Do you have any videos on making my own home time machine?

[@bavarianautosport]

We have the time machine video in production now. Should be done by April first.

[@mhknapp1]

Nice to recommend the Bentley manual - however Bentley doesn't have a manual for my car - 2007 BMW Z4M Roadster

[@grantflowers62]

I'm going to buy a single mass flywheel conversion kit for my 2001 Z3 3.0i and I was wondering about replacing the master cylinder if you're going to replace the slave cylinder anyway? Is that necessary? Otherwise, very informative video. Thanks

[@clefchef8121]

"Torque it to the specification" - it would be nice to know those specifications, could you just mention those on the video?

[@gregorytolson4621]

Fcp euro has a video showing all the torque specs on an e46

[@bavarianautosport]

2003 530i

[@AutmotiveProcedures]

Hi, I work on a lot of German cars and have seen a lot of these dual mass problems. We always recommend the upgrade to the 1 piece flywheel and I have one in my 2006 Jetta but I have noticed it has a very slight jerking feeling in 1st and 2nd gear when compared to a customer with a 2 piece. Have you personally noticed any roughness compared the the dual mass? It might just be me being picky

[@molliarti]

The fork of a BMW E36 has hand (right or left) or is indiferent? Thanks.

[@bavarianautosport]

Brian Flomer - We can't reply directly to your comment as it was sent in via Google. The starter does need to be disconnected from the transmission bell-housing. You can leave the starter in place, but the two mounting bolts must be removed. If the transmission is moving but will not fully separate, we would say that either the starter is still bolted in or the small bolt on the shield plate is still in-place (on the passenger side, from the front). If the trans will not move at all, you likely still have a main mounting bolt to remove.

[@achristopher745]

Brian, if you have all bolts off (including the metal shield), the dowel pin in the starter may be the suspect. It can become corroded and can take a great deal of force to break loose. Spray some penetrating oil on it and use some extensions with a metal punch to push it from the rear toward the front of your car. Good luck!

[@bavarianautosport]

Adam Krick - Good input Adam. We've dealt with that!

[@achristopher745]

Hey Craig Bettridge, the starter is only attached to the transmision with two bolts that you remove on the transmission side. There's also a dowel that I mentioned in a comment that gave me a very difficult time. I took some sand paper to clean it up before reinstalling it. I'm not sure if you've ever heard of it or not, but www.realoem.com/bmw/select.do has very helpful diagrams specific to your BMW. Just punch in the last 6 characters of your VIN at the top and it's pretty easy from there.

[@cbettridge]

Adam Krick thank you for the link!! I noticed it after sticking my head right up in the drive shaft well.

[@donnieblingin7704]

Bavarian Autosport how much would a job like this cost on a e38 740il

[@tevin3316]

Nice video...

[@ailarvadi958]

Hi, what kind of gasket sealer or maker did you use on the steel gasket and did you use any grease or anything on the new crank seal as well?

[@oneminutefixed5003]

been driving for months with a worn out clutch :\ i'll have to replace it in the next 2 months, my biggest concern (besides the cost) is whatever problems may arise when removing that piece, my mechanic said i possibly had an oil leak into the clutch and that caused the clutch do slide in higher rpm. In case of an oil leak, will the seals and gasket paste be enough to solve the problme?

[@CompCrasher86]

I like the pilot bearing tool used in this video (not the slide hammer type). Where can we find it?

[@Patryc]

looks easy

[@absolutegtr]

Excellent video! How do I know my 2004 330ci 6-spd has a SAC? It is as 115k miles now and slipping.

[@rr29871]

Hi, fantastic video, will get mine changed next month, I was only wondering what is that dioxide mechanical penetrant? I use wd40 professional, but I can bet this what you use I by far better 😁

[@bavarianautosport]

By strongest, do you mean most power? In this case, the S38 (as offered in the E34 M5) offers far more horsepower than the M50 (E36 325i, E34 525i, etc.)..

[@bavarianautosport]

Just a small 10mm hex-haed bolt.

[@och3696]

can i do it same way on N46B18?i want to install clutch set ,mine by vin is 228mm but all i find on net is 230 ,will it fit?why on other videos guys instal sac with special tool nr.212170 not only centring tool

[@Asank6969]

thank you very much

[@arturosanchez1778]

i have a question what does the bolt on the flex shield look like

[@bavarianautosport]

Well ..... if the head is too beat up to accept the Torx socket, at this point, there isn't much you can do besides pulling the engine and transmission so you can actually get to the bolt. You can try hammering on a regular 6-point socket (match one up with one of the removed bolts), as a last ditch effort. If you can get one on tightly, try to turn it by hand ... not with an air-tool.

[@shivankafroshy830]

Can you make a video for clutch and flywheel replacement for a 2006 E60 M5 ? or is it the same process as this video ? Thanks!

[@colmtully2943]

Hi I'm replacing the clutch and flywheel in my e39. I'm having trouble getting the gearbox back in. The disc is lined up put even though I turn the gearbox and shaft it won't slide in. Any advice thanks

[@ilkinhamidov]

Hello team. Excellent work. Please advise: i got e46 m3 bmw. It has click noise coming from drivetrain during each gear change ( you can control the noise by clutch pedal) and rattling noise when you switch off the engine on neutral gear. However if you engage clutch during engine switch off the noise disappears. Any idea? Thanks.

[@BrianFlomer]

I'm in the process of replacing my clutch but I can't get the transmission away from the input shaft. I'm pretty sure I took all the inverted torx off, but is there a hex bolt up there also? (someone told me they thought they saw one at the top). Also, Do you have to remove the starter on BMWs? Any info will help

[@volvot5turbo]

Does the crankshaft position sensor need removing? Just got my 330d E46 back and it appears to be misfiring at high revs, juddering at high revs, chucking out clouds of black smoke when wide open throttle and also throwing the DDE light when hoofing in 3rd from low revs. I've tried everything else and now suspect the Crankshaft position sensor that wasn't removed during installation has got somewhat damaged? Also get mid section vibrations at low revs full throttle......

[@Ali-uv3dz]

how is the car driving/during shifting after changing the clutch do you hear some sound or do you feel anything

[@carscoffeeandmischief]

This might be a dumb question; will this be somewhat the same for an 06 530i with an SMG transmission?

[@bavarianautosport]

For the most part, yes. You will be dealing with the SMG parts that operate the clutch and shifter hydraulically, but the transmission and clutch assemblies are pretty much the same.

[@victorlittle3982]

Just replacing clutch and not fly wheel on my 2003 m3 dosent the fly wheel need to pre loaded when installing new clutch?

[@JuanAguilarPerez-ce9ti]

Would this process be similar for a 2006 550i with the SMG transmission?

[@bavarianautosport]

Sorry for the delay in replying. Are you still having trouble with your clutch install?

[@levenlifee]

hi, does the e46 AMS clutch fit the 6 speed clutch or are they different?

[@user-rx1pu8bg1b]

I have a e46 330xd with 5 speed manual transmission, sometimes when i press the clutch to the bottom it makes noise like knocking or squeaking, it dont knocks when car in neutral, what do you think is the DMF almost gone or its something else?

[@GlennKaler]

What is the part number for the Pilot Bearing Removal Tool? I went to bavauto and found the Slide Hammer Pilot Bearing Puller CTA Tools but not the one used in the video.

[@molliarti]

How is a bmw position clutch fork please,many thanks.

[@raul4sactown10]

I also removed the locking plate before putting it in the transmission, can that be the problem?

[@bavarianautosport]

Raimondas - We can't reply directly to your comment as it was sent in via Google. The MechanicAll penetrant is far superior to WD40, but does cost more. Click the link below: www.bavauto.com/fland.asp?part=M20S-6N

[@volvot5turbo]

Is this necessary? Just had my flywheel done (E46 330D) and they didn't remove the sensor. Now I get dde light on, black smoke at high revs/WOT and juddering at high revs when this happens.......no codes on scanner though except for rail plausibility too high (too much fuel I suspect judging by black smoke). Tried everything else and now suspect timing is out. Tickover is fine though and normal driving appears ok. Slight vibration at tickover now (more like resonance). Thanks :-)

[@BuiltForRedline]

Great. Don't forget to check ours

[@bavarianautosport]

Well ..... if the engine is running properly and smoothly, then the next probable cause may indeed be a very worn out dual mass flywheel. Typically, you would not have a shake at idle, due to a worn out DMF, but it is conceivable that a very loose one could cause an idle vibration.

[@kimomed1988]

Should I renew the Bell Housing transmission bolts???

[@joeyfischer2044]

hey guys i have a big question. I am pulling my clutch out of my old motor and want to swap to my new motor. it is SAC do i need to rest the SAC with the special tools or will it adjust by itself?

[@joserod4091]

could I use this video with my 2002 BMW 325i 5 speed to change my clutch

[@Adamdrew0810]

Hey I just had clutch replaced on 02 e39 m5 and now it's in limp mode . Any ideas what caused this ? Please help!

[@bavarianautosport]

Unfortunately, we can't have every agent being a full 100% technician. However, we should have offered further assistance to you. Anyway, if you crossed the sensors and have then installed in the wrong positions, the engine will not run. Secondly, if the pin on the side of the flywheel was damaged, the position sensor will have nothing to read. Did you replace the flywheel, by chance?

[@christiangrad5696]

Installing short shift kit

[@christiangrad5696]

Sorry. Can be deleated.

[@bigdaddy377able]

my friend also has an 85 325e bmw ,would the procedure be similar as well ?

[@oscarlamata5180]

One question....the rotary movement It had the dual-mass flywheel was good or not?...thanks

[@demoniacRACING]

Hi, ist there available solid fly wheel conversion kit for bmw E60 530d? and worth to fix it?

[@kris12211221]

I watched these vids before replacing the clutch in my 87 325, they were a big help, but for some reason the car wont start. just wondering if this could have anything to do with the sensors on the outside of the bell housing, I did have to remove them but I dont think they were damaged at all. I had called the number you provided but the service rep was less than helpful. Im hoping someone might be able to help me out, I just hope the same guy isnt in charge of answering the emails lol, thanx

[@21497bmw]

What size Allen wrench do I need to use to take off the pressure plate bolts

[@mortoncg1018]

I need a flywheel for my 2004 e60 I cannot find it here in Iraq I wonder if all manual transmission e60 have the same flywheel design or there's a difference?

[@Dicer328]

At 8:00 Otto is absolutely INCORRECT about using that tiny amount of rotational freedom to determine that the DMF is worn out. To prove it to you just search youtube for a video called "The LuK DMF - its function, diagnosis and repair " and go to 3:28 of that video to see what the internals look like. Keep in mind that this channel is about SELLING parts.

[@pshyxory2678]

Is it the same process for E60 M5 2006 ?

[@afhostie]

BavarianAuto Is there a mileage that we would want to do this to replace the rear main seal even if the clutch isn't slipping yet?

[@DavidFKturbo]

Get rid of dual-mass for much smoother operation, then why is there dual-mass? Thanx for awesome vids/ David, Sweden

[@scottycuk]

Because he is talking utter BS, it’s not smoother, just less issues

[@maciejweber4256]

Can you please list all of those parts you have replaced? That would be kind.

[@j.gtheautotech8455]

What glove brand do you use!! Those look like they dont tare easily

[@tanselozturk2688]

Hello... I have a question.. - This parts same for 09/2003 325i with ''SMG'' transmission? And Do all transactions the same? Thank you in advance for your attention to this matter.

[@danpage1985]

this man loves the rattler

[@hooperwille]

Does this video apply also to E38 with manual transmission?

[@Ninchaki]

hello i m facing whit a problem on my e90 320d 164hp on a cold start when i want to take off in first gear i have judder is that from the clutch or something else?

[@mohussain136]

will the tools and parts work for a diesel engine aswell