aja540i 1901 Report post Posted September 24, 2015 Picked these up last night, need to get a few special tools and will then be chucking it all in the wagon. Will try to take some photos to throw in here as well. Using the Bentley manual to guide me along but feel free to share any tips or tricks you know of... 1 Quote Share this post Link to post Share on other sites
Allanw 1051 Report post Posted September 25, 2015 I have a tip: move all the crap off your hoist, and do it on that Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted September 25, 2015 I have a tip: move all the crap off your hoist, and do it on that HAH, i have to move 3 cars to even get near it! Quote Share this post Link to post Share on other sites
Ahmedsinc 414 Report post Posted September 25, 2015 If you have a semi-capable teenager with a passing interest in cars make him / her do it, under your 'supervision'. Means someone else does all the tedious stuff while under the guise of 'learning' something new. Works best if bribed with pizza / movie tickets / a beer as long as the relevant parents aren't aware Hell, thats how my old man got the clutch replaced in the Morris Minor and the Telstar a few years later! Then again, I always was a bit gullible........ That kit looks like it was expensive - how much was the new DM flywheel worth? 2 Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted September 25, 2015 If only i had access to a potential mechanic, all the nephews are a bit too young yet. Flywheel was $1731.45 +gst Clutch kit $450.59 + Pilot bearing $37.04 + Clutch bolts $10.61 + All up $2564.10 from Jerry Clayton BMW. Quote Share this post Link to post Share on other sites
Ahmedsinc 414 Report post Posted September 25, 2015 Ahh, thats a shame! Shite, thats eye-watering stuff! Clutch kit is cheaper than I guessed though. Quote Share this post Link to post Share on other sites
KwS 2376 Report post Posted September 26, 2015 Anything with a dual mass flywheel is going to be expensive to replace. Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted September 27, 2015 Some progress, have aquired / made / borrowed the special tools required... Torx T60 bit, has to be modified slightly. Alignment tool, thanks Martin. Home made flywheel lock. Bolted on... Old flywheel off... Quote Share this post Link to post Share on other sites
kiwi535 538 Report post Posted September 27, 2015 a manual 540 touring...touring? Rare(and nice). Quote Share this post Link to post Share on other sites
BreakMyWindow 1870 Report post Posted September 27, 2015 That's a nice and dry rear main seal which is a bonus. Perfect opp to replace the bushings and clips for the gear shift while the drive shaft is off. Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted September 27, 2015 That's a nice and dry rear main seal which is a bonus. Perfect opp to replace the bushings and clips for the gear shift while the drive shaft is off. Rear main seal has been done since i got the car, might do the shift link while im under there, i have a factory short shift but am saving that for the e36. Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted September 27, 2015 a manual 540 touring...touring? Rare(and nice). Yeah, i will miss it when it is sold but cant justify keeping it and the m5, and the e36, and the e21. Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted September 30, 2015 More progress, thanks to daylight saving... Cleaning out the threads with M12 x 1.5 tap New pilot bearing and flywheel fitted, flywheel bolts torque to 77 ft-lb, 105Nm. Clutch plate fitted with alignment tool Pressure plate fitted, M8 bolts torque to 18 ft-lb, 24 Nm. Now i just have to wrangle the gearbox back in!! 1 Quote Share this post Link to post Share on other sites
Allanw 1051 Report post Posted September 30, 2015 ....Now i just have to wrangle the gearbox back in!! Then post of vid of the bedding in burnout... Quote Share this post Link to post Share on other sites
c.robertson00 11 Report post Posted October 1, 2015 Do the holes in the crank for the flywheel bolts go all the way through? If so I would have thought that any metal particles you cleaned off the threads with the tap just ended up inside your engine... Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted October 1, 2015 Do the holes in the crank for the flywheel bolts go all the way through? If so I would have thought that any metal particles you cleaned off the threads with the tap just ended up inside your engine... No, they are blind holes. I used a bottom tap to clean the threads then blew them out with compressed air, probably a bit ocd but its not much extra work. Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted October 6, 2015 Got carried away over the weekend and pulled the starter motor out, stripped it down, cleaned, lubricated, and put it all back together. Gearbox went back in this evening with some help from my faithfull assistant/ wife! 1 Quote Share this post Link to post Share on other sites
Allanw 1051 Report post Posted October 6, 2015 Got carried away over the weekend and pulled the starter motor out, stripped it down, cleaned, lubricated, and put it all back together. Gearbox went back in this evening with some help from my faithfull assistant/ wife! Quote Share this post Link to post Share on other sites
aja540i 1901 Report post Posted October 10, 2015 So, everything is back in and tightened up, just waiting for the battery to charge so i can fire it up and see what happens.... Quote Share this post Link to post Share on other sites
