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The Comprehensive S85 Clutch + Flywheel Replacement Thread

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    The Comprehensive S85 Clutch + Flywheel Replacement Thread

    Hello Everyone!

    My clutch finally gave up. The car has done 80,000 kms. So I took the opportunity and decided to get a little maintenance done as well.

    Below is the parts list.

    21212283089 Clutch 1 (Sachs)
    23117564680 Guide Bush 1
    21511223328 Ball pin 1 (Comes with the clutch kit)
    21517570284 Spring Clip 1 (Comes with the clutch kit)
    21517848830 Clutch release bearing 1 (Comes with the clutch kit)
    07129905539 ISA Screw 9 (Use the originals if they are stainless steel)
    21511223302 Clutch release fork lever 1
    21212229955 Flywheel 1 (Luk)
    11211720310 Grooved ball bearing 1
    11211736881 Dowell 1
    23017838938 Clutch slave cylinder 1
    23017837428 Clutch position sensor 1
    61366901469 SMG Pump relay 1 (Black)
    12631742690 Transmission Pump relay 1 (Red)
    11217838071 Shaft seal 1
    83220309031 Oil for manual transmission MTF LT-2 3 Liters (BMW recommends a change interval of 3 engine oil changes, which is like 60k, kms. The change interval for the diff oil is the same. From now on, I will change it every year.)

    17212283111 Oil Strainer SMG 1 (Not necessary to replace. Old one can be cleaned and used again)
    07119963300 Gasket ring SMG 4
    CHF-11S SMG Fluid 2

    "And Here We Go" - Joker - YouTube

    Exhaust, heat shields and drive shaft need to come off before we can have some fun.



    The old flywheel, used very well obviously.





    The clutch also used very well.



    Bell housing with the clutch off.



    New clutch and flywheel.





    Bell housing prepped with new parts.



    New clutch and flywheel ready to go in.



    Installed.



    Drain plug for the transmission oil.



    This is what came out. Wish I had changed it earlier. Added to my annual maintenance schedule.



    Transmission oil strainer with all the crap on it.



    All cleaned up and ready to go in.



    Ran the adaptations and the transmission will not adapt. Kept getting the below error.



    Diagnosis. The heat from the exhaust burned these cables and the transmission sensor and cable is fried. Most probably short circuit.





    The solution. New valve body complete with everything. You cannot buy the wiring and sensor from BMW. OUCH! This thing is expensive. I had the option to get a used one from eBay, but decided I will put my money on a new one.

    So, off comes the tranny again and we get to heat insulate that prick as much as possible. Below will give a fair idea of what we did. Hopefully, it will last a little longer this time.



















    How it looks like all done.



    Fix everything up and run the adaptations again and everything goes smooth.

    Now to the boring task of breaking in the clutch for 1000 kms. BMW recommends 1000 shifts at moderate rpms and load.

    - - - - - - - - - -

    Once again oceans of gratitude to the team at Octane. Great workmanship and ingenuity.
    sigpic

    http://www.youtube.com/user/hashaikh11

    #2
    Use S1, the slowest ratio, till 500 kms, then start breaking in moderately.

    Looks like a job well done to me My diff oil is due as well as I'm approaching 75k.

    Enjoy the ride Mr. Hasan :)
    Drive To The Satisfaction... A Dreamer's Pursuit

    2013 F10 M5 - M Drivers Package
    Alpine White / Sakhir Orange

    Mods: ZCP Kidney Grilles

    2009 E92 M3 - M Drivers Package
    Melbourne Red / Imola Red [Manual] (SOLD)

    Mods: Full Catless AlphaMale Performance Valvetronic Exhaust | Macht Schnell Stage 2 Air Intake | H&R Lowering Springs | ECS Tuning Spacers | Carbon Fiber Front Splitters | Glossy Black Kidney Grilles | Plasti-Dipped Fender Grilles | LCI Tail Lights | Carbon Fiber H-Style Diffuser | Stage 2 Tune (Simon MotorSport) | Macht Schnell Pulleys | Carbon Fiber LowKick Trunk Spoiler

    2003 E46 M3 - Carbon Black / Imola Red (BLOWN)
    Mods: Rear Smoked LEDs | Front Smoked Corner Lights | 4300K Phillips 85122+ Bulbs | BMC Drop-In Panel | Matt Black Kidney Grilles | 7500K CCFL | Matt Black Side Grilles | FOX SS Muffler | VIEZU Remap | CSL Carbon Fiber Splitters | EvoSport Under Drive Pulley Kit | K&N Cold Air Intake | K&N Scoops | Hawk Carbon-Ceramic Brake Pads | R1Concepts Zinc-Coated Cross-Drilled Rotors | Agency Power Stainless Steel Braided Brake Lines | Hyper Black M3 Competition Rims | FXR Bi-Xenon Projectors w/ Clear Lenses | 70% 3M Tinting
    1997 E39 528i - Champagne Beige / Sand Beige (SOLD)
    Mods: Front & Rear OEM Facelift | K&N Cold Air Intake | Straight Pipes | MAF Delete | Custom Made Air Intake Elbow | 3.15 LSD Differential | SplitFire Spark Plugs | E36-7 Z3 OEM 17" Rims | 50% 3M Tinting

    Need Assistance?
    eMail:
    Rafik@bmwclubuae.com


    @Rafik_Jabbour (Link)

    Comment


      #3
      Thanks Rafik

      I will follow your advice on the break-in.

      Change your transmission oil as well.
      sigpic

      http://www.youtube.com/user/hashaikh11

      Comment


        #4
        I've changed the tanny oil few thousands back. Diff oil is on my list.
        Drive To The Satisfaction... A Dreamer's Pursuit

        2013 F10 M5 - M Drivers Package
        Alpine White / Sakhir Orange

        Mods: ZCP Kidney Grilles

        2009 E92 M3 - M Drivers Package
        Melbourne Red / Imola Red [Manual] (SOLD)

        Mods: Full Catless AlphaMale Performance Valvetronic Exhaust | Macht Schnell Stage 2 Air Intake | H&R Lowering Springs | ECS Tuning Spacers | Carbon Fiber Front Splitters | Glossy Black Kidney Grilles | Plasti-Dipped Fender Grilles | LCI Tail Lights | Carbon Fiber H-Style Diffuser | Stage 2 Tune (Simon MotorSport) | Macht Schnell Pulleys | Carbon Fiber LowKick Trunk Spoiler

        2003 E46 M3 - Carbon Black / Imola Red (BLOWN)
        Mods: Rear Smoked LEDs | Front Smoked Corner Lights | 4300K Phillips 85122+ Bulbs | BMC Drop-In Panel | Matt Black Kidney Grilles | 7500K CCFL | Matt Black Side Grilles | FOX SS Muffler | VIEZU Remap | CSL Carbon Fiber Splitters | EvoSport Under Drive Pulley Kit | K&N Cold Air Intake | K&N Scoops | Hawk Carbon-Ceramic Brake Pads | R1Concepts Zinc-Coated Cross-Drilled Rotors | Agency Power Stainless Steel Braided Brake Lines | Hyper Black M3 Competition Rims | FXR Bi-Xenon Projectors w/ Clear Lenses | 70% 3M Tinting
        1997 E39 528i - Champagne Beige / Sand Beige (SOLD)
        Mods: Front & Rear OEM Facelift | K&N Cold Air Intake | Straight Pipes | MAF Delete | Custom Made Air Intake Elbow | 3.15 LSD Differential | SplitFire Spark Plugs | E36-7 Z3 OEM 17" Rims | 50% 3M Tinting

        Need Assistance?
        eMail:
        Rafik@bmwclubuae.com


        @Rafik_Jabbour (Link)

        Comment


          #5
          Good job. Very nicely done.
          EURO 04 M3
          Current Mods:GC DA's, Eibach Sways, PF RTABs, RE RCAs, INTRAVEE II + Alpine KCA-420i, Black Roundels, ///MFEST Badges, Depo Corners, M5 SMG Knob, Screen protector for OEM 16:9 display, VCSL: Bumper + Race Lip, CF Trunk, CF Diffuser, DIETZ TV in Motion, AP Headers, RT Cats, SS Res X-pipe, SS Race, Z8 Starter Button, Lamin-X, GM SMG Paddles, OEM CSL Steering, OEM CSL interior, OEM CSL Intake, EVOLVE Alpha-N Tune, BBS CH's, FX-R Projectors + 3k D2S, ST40's, DINAN Rear Strut Brace

          Comment


            #6
            Originally posted by RAFiK View Post
            I've changed the tanny oil few thousands back. Diff oil is on my list.

            Very nice. I have a few questions.

            What was the mileage at which you changed the oil?
            What was the condition of the oil?
            What oil did you use?
            How much oil did it take?
            At what mileage will you do the next service?

            Also, you should share with everyone when you do a service like this.

            Let us know how the diff oil turns out. I change my diff oil every year and it comes out real dirty.

            Thanks

            - - - - - - - - - -

            Originally posted by 0-60 View Post
            Good job. Very nicely done.
            Thank you sir
            sigpic

            http://www.youtube.com/user/hashaikh11

            Comment


              #7
              I changed it at 65,000 as I recall +/- 5,000 kms.

              It came out black :\ I was surprised honestly because I didn't think the condition would be that bad.

              I changed it with Redline MTL Manual Transmission Fluid 75w80 that was recommended by ECS Tuning.

              www.ecstuning.com/BMW-E92-M3-S65_4.0L/ES1502/

              Next service at 100,000 I think. I'll change the transmission oil at every 50k I think.
              Drive To The Satisfaction... A Dreamer's Pursuit

              2013 F10 M5 - M Drivers Package
              Alpine White / Sakhir Orange

              Mods: ZCP Kidney Grilles

              2009 E92 M3 - M Drivers Package
              Melbourne Red / Imola Red [Manual] (SOLD)

              Mods: Full Catless AlphaMale Performance Valvetronic Exhaust | Macht Schnell Stage 2 Air Intake | H&R Lowering Springs | ECS Tuning Spacers | Carbon Fiber Front Splitters | Glossy Black Kidney Grilles | Plasti-Dipped Fender Grilles | LCI Tail Lights | Carbon Fiber H-Style Diffuser | Stage 2 Tune (Simon MotorSport) | Macht Schnell Pulleys | Carbon Fiber LowKick Trunk Spoiler

              2003 E46 M3 - Carbon Black / Imola Red (BLOWN)
              Mods: Rear Smoked LEDs | Front Smoked Corner Lights | 4300K Phillips 85122+ Bulbs | BMC Drop-In Panel | Matt Black Kidney Grilles | 7500K CCFL | Matt Black Side Grilles | FOX SS Muffler | VIEZU Remap | CSL Carbon Fiber Splitters | EvoSport Under Drive Pulley Kit | K&N Cold Air Intake | K&N Scoops | Hawk Carbon-Ceramic Brake Pads | R1Concepts Zinc-Coated Cross-Drilled Rotors | Agency Power Stainless Steel Braided Brake Lines | Hyper Black M3 Competition Rims | FXR Bi-Xenon Projectors w/ Clear Lenses | 70% 3M Tinting
              1997 E39 528i - Champagne Beige / Sand Beige (SOLD)
              Mods: Front & Rear OEM Facelift | K&N Cold Air Intake | Straight Pipes | MAF Delete | Custom Made Air Intake Elbow | 3.15 LSD Differential | SplitFire Spark Plugs | E36-7 Z3 OEM 17" Rims | 50% 3M Tinting

              Need Assistance?
              eMail:
              Rafik@bmwclubuae.com


              @Rafik_Jabbour (Link)

              Comment


                #8
                Originally posted by RAFiK View Post
                I changed it at 65,000 as I recall +/- 5,000 kms.

                It came out black :\ I was surprised honestly because I didn't think the condition would be that bad.

                I changed it with Redline MTL Manual Transmission Fluid 75w80 that was recommended by ECS Tuning.

                www.ecstuning.com/BMW-E92-M3-S65_4.0L/ES1502/

                Next service at 100,000 I think. I'll change the transmission oil at every 50k I think.


                Thanks for sharing the information.

                I had the same feeling when I saw the oil that came out of my transmission.

                The BMW OEM is also 75W-80.

                Please post on the forums when you do your next service. I will also change the tranny oil after 40k kms and post here.

                Thanks
                sigpic

                http://www.youtube.com/user/hashaikh11

                Comment


                  #9
                  Will do! :)
                  Drive To The Satisfaction... A Dreamer's Pursuit

                  2013 F10 M5 - M Drivers Package
                  Alpine White / Sakhir Orange

                  Mods: ZCP Kidney Grilles

                  2009 E92 M3 - M Drivers Package
                  Melbourne Red / Imola Red [Manual] (SOLD)

                  Mods: Full Catless AlphaMale Performance Valvetronic Exhaust | Macht Schnell Stage 2 Air Intake | H&R Lowering Springs | ECS Tuning Spacers | Carbon Fiber Front Splitters | Glossy Black Kidney Grilles | Plasti-Dipped Fender Grilles | LCI Tail Lights | Carbon Fiber H-Style Diffuser | Stage 2 Tune (Simon MotorSport) | Macht Schnell Pulleys | Carbon Fiber LowKick Trunk Spoiler

                  2003 E46 M3 - Carbon Black / Imola Red (BLOWN)
                  Mods: Rear Smoked LEDs | Front Smoked Corner Lights | 4300K Phillips 85122+ Bulbs | BMC Drop-In Panel | Matt Black Kidney Grilles | 7500K CCFL | Matt Black Side Grilles | FOX SS Muffler | VIEZU Remap | CSL Carbon Fiber Splitters | EvoSport Under Drive Pulley Kit | K&N Cold Air Intake | K&N Scoops | Hawk Carbon-Ceramic Brake Pads | R1Concepts Zinc-Coated Cross-Drilled Rotors | Agency Power Stainless Steel Braided Brake Lines | Hyper Black M3 Competition Rims | FXR Bi-Xenon Projectors w/ Clear Lenses | 70% 3M Tinting
                  1997 E39 528i - Champagne Beige / Sand Beige (SOLD)
                  Mods: Front & Rear OEM Facelift | K&N Cold Air Intake | Straight Pipes | MAF Delete | Custom Made Air Intake Elbow | 3.15 LSD Differential | SplitFire Spark Plugs | E36-7 Z3 OEM 17" Rims | 50% 3M Tinting

                  Need Assistance?
                  eMail:
                  Rafik@bmwclubuae.com


                  @Rafik_Jabbour (Link)

                  Comment

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