How to Change Clutch Kit on BMW 5 Saloon (E60)

Important Information

This replacement procedure is applicable for the following models:

• BMW 5 Saloon (E60) 520i 2.2
• BMW 5 Saloon (E60) 525i 2.5

Note: The steps may vary slightly depending on the car's design.

This tutorial is based on a similar replacement procedure for a BMW 3 Convertible (E46) 320Ci 2.2.

Tools You Might Need

Replacement Procedure

AUTODOC experts recommend replacing the entire clutch kit assembly, including the pressure plate, clutch disc, and release bearing. Ensure the engine is switched off before commencing any work.

1. Open the bonnet.
2. Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
3. Open the boot lid.
4. Remove the battery cover.
5. Unscrew the negative battery terminal fastener using a drive socket #10 and a ratchet wrench.
6. Disconnect the earth cable terminal from the battery.
7. Lift the car using a jack or place it over an inspection pit.
8. Unscrew the engine splash guard fasteners using a Phillips screwdriver.
9. Remove the engine splash guard.
10. Prop up the subframe reinforcement bracket using a hydraulic transmission jack.
11. Unscrew the subframe reinforcement bracket fasteners using a drive socket #16 and a ratchet wrench.
12. Remove the subframe bracket.
13. Tip: Make marks on the front propshaft coupling to indicate its position.
    Unscrew the propshaft coupling fasteners using a combination spanner #18, a drive socket #18, and a ratchet wrench.
14. Unscrew the clutch slave cylinder fasteners using a drive socket #13 and a ratchet wrench.
15. Remove the clutch slave cylinder.
16. Disconnect the transmission sensor connector.
17. Prop up the gearbox support using a hydraulic transmission jack.
18. Unscrew the fasteners that connect the gearbox support to the car body using a drive socket #13 and a ratchet wrench.
19. Unsnap the locking pin on the shift lever support arm using a crowbar.
20. Remove the cotter pin.
21. Disconnect the shift lever support arm.
22. Remove the selector rod retaining clip.
23. Detach the selector rod.
24. Clean the exhaust system fastener using a wire brush and WD-40 spray.
25. Unscrew the exhaust system fasteners using a combination spanner #13, a drive socket #13, and a ratchet wrench.
26. Remove the exhaust system fastener.
27. Unscrew the exhaust system bracket fasteners from the car body using a drive socket #13 and a ratchet wrench.
28. Remove the exhaust system bracket.
29. Use a metal hook to hang the exhaust line to the suspension components or to the car body.
30. Unscrew the fasteners of the exhaust heat shield using a drive socket #10 and a ratchet wrench.
31. Remove the exhaust heat shield.
32. Unscrew the fasteners of the propeller shaft centre support bearing using a drive socket #13 and a ratchet wrench.
33. Disconnect the propshaft centre bearing from the car body.
34. Move the propeller shaft aside.
35. Tip: Secure the propeller shaft to the car body to prevent injuries.
    Remove the propshaft coupling.
36. Unscrew the lower fasteners that connect the gearbox to the engine using Torx E11 and a ratchet wrench.
37. Remove the fastening bolts.
38. Unscrew the engine starter fasteners using Torx E12 and a ratchet wrench.
39. Move the starter away from the gearbox.
40. Unscrew the fasteners that connect the gearbox to the engine block using Torx E14 and a ratchet wrench.
41. Remove the fastening bolts.
42. Disconnect the gearbox from the engine using a crowbar.
43. Remove the gearbox using a hydraulic transmission jack.
44. Install the engine flywheel locking tool using a clutch tool kit.
45. Unscrew the pressure plate fasteners using HEX No.H6 and a ratchet wrench.
46. Remove the fastening bolts.
47. Remove the pressure plate together with the clutch disc using a crowbar.
48. Clean the clutch kit mounting seats using all-purpose cleaning spray.
49. Install the new pressure plate together with the clutch disc.
50. Tip: Be careful not to damage the part.
    Align the clutch disc using a clutch tool kit.
51. Install the fastening bolts.
52. Screw in the pressure plate fasteners using HEX No.H6 and a ratchet wrench.
53. Tighten the pressure plate fasteners using HEX No.H6 and a torque wrench to 25 Nm torque.
54. Unscrew the locking plate of the pressure plate using HEX No.H14 and a ratchet wrench.
55. Tip: When unscrewing it, the clutch diaphragm spring may click.
    Remove the flywheel locking tool.
56. Remove the release bearing.
57. Remove the clutch release fork lever.
58. Clean the clutch release bearing mounting seat using all-purpose cleaning spray.
59. Treat the release bearing mounting seat using a multipurpose grease.
60. Install the clutch release fork lever.
61. Install the new release bearing.
62. Install the gearbox using a hydraulic transmission jack.
63. Tip: Take care to prevent the gearbox from being unsupported (hanging).
    Install the fastening bolts.
64. Tighten the lower fasteners that connect the gearbox to the engine using Torx E11 and a ratchet wrench.
65. Install the engine starter.
66. Screw in the engine starter fasteners using Torx E12 and a ratchet wrench.
67. Install the fastening bolts.
68. Screw in the fasteners that connect the gearbox to the engine block using Torx E14 and a ratchet wrench.
69. Tighten the engine starter fasteners using Torx E12 and a torque wrench to 43 Nm torque.
70. Tighten the fasteners that connect the gearbox to the engine block using Torx E14 and a torque wrench to 72 Nm torque.
71. Tighten the lower fasteners that connect the gearbox to the engine using Torx E11 and a torque wrench to 22 Nm torque.
72. Attach the shift lever support arm.
73. Install the cotter pin.
74. Secure the locking pin on the shift lever support arm.
75. Attach the selector rod.
76. Attach the selector rod retaining clip.
77. Connect the propeller shaft to the gearbox flange via the propshaft coupling.
78. Align the propeller shaft flange with the mark you made.
79. Tighten the propshaft coupling fasteners using a combination spanner #18, a drive socket #18, and a torque wrench to 100 Nm torque.
80. Attach the propshaft centre bearing to the car body.
81. Tighten the fasteners of the propeller shaft centre support bearing using a drive socket #13 and a torque wrench to 32 Nm torque.
82. Prop up the gearbox support using a hydraulic transmission jack.
83. Tighten the fasteners that connect the gearbox support to the car body using a drive socket #13 and a torque wrench to 35 Nm torque.
84. Prop up the exhaust line using a hydraulic transmission jack.
85. Install the exhaust heat shield.
86. Tighten the fasteners of the exhaust heat shield using a drive socket #10 and a ratchet wrench.
87. Install the exhaust system fastener.
88. Tighten the exhaust system fasteners using a drive socket #13 and a torque wrench to 22 Nm torque.
89. Install the exhaust system bracket.
90. Tighten the fasteners that connect the exhaust system bracket to the car body using a drive socket #13 and a torque wrench to 22 Nm torque.
91. Attach the transmission sensor connector.
92. Install the clutch slave cylinder.
93. Tighten the clutch slave cylinder fasteners using a drive socket #13 and a torque wrench to 22 Nm torque.
94. Install the subframe bracket.
95. Tighten the subframe reinforcement bracket fasteners using a drive socket #16 and a torque wrench to 59 Nm torque +90°.
96. Install the engine splash guard.
97. Tighten the engine splash guard fasteners using a Phillips screwdriver.
98. Lower the car.
99. Connect the earth cable terminal to the battery.
100. Screw in the negative battery terminal fastener using a drive socket #10 and a ratchet wrench.
101. Install the battery cover.
102. Close the lid of the luggage compartment.
103. Run the engine for a few minutes to ensure proper operation.
104. Shut off the engine.
105. Remove the fender protection cover.
106. Close the bonnet.

WELL DONE! ?

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Disclaimer: This document provides general recommendations for repair and replacement. AUTODOC is not liable for any loss, injury, or damage resulting from incorrect use or misinterpretation of the information provided. AUTODOC is not liable for any errors or omissions in this guide and advises consulting specialists for professional advice. AUTODOC is not liable for the incorrect or hazardous use of equipment, tools, and car parts. Safety rules should always be observed. Using low-quality auto parts may compromise road safety.

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