Looks Like Clutch Time

[Uturn540]

After 122k miles am starting to get some slip, but only on hard upshifts. The rest of the time no chatter and smooth engagement at the middle of pedal travel. I figure the flywheel is still good and I can drive it for a while till I have the parts and a nice warm day. Definitely doing the CDV while its apart and more than likely going with the M5 clutch kit. Difficult choice is what brand. Did the clutch in my HD Ford a few years back with a LUK clutch and no issues. Did a Jeep Wrangler with a LUK clutch two years ago only to have the clutch fail in a year and a half due to the pressure plate flanges not reaching the alignment pins on the flywheel. Ended up replacing it with a Sachs which is the way I am leaning at this time. Of course I am always open to suggestions and tips.

[JimLev]

Had the same slip problem at 103K with hard shift when using the juice. No juice no slip.
I put the stock clutch, pp, and release bearing in (think it was Luk) and all is still good. That was about 8 years ago.
Sort of wish I did the M5 stuff which I will use next time.

[Uturn540]

I think it has more to do with the pressure plate springs weakening over time. M5 stuff is so that, if and when I finally lose it and I can just join the dead pool.

[waters17]

I recently overhauled my clutch/flywheel. I drove on the slipping clutch for quite a while. IIRC any pedal over 3k rpm would cause it to slip.

For the clutch, I went with the LUK M5 kit (03-042), but Sachs seems like a great choice. If you do go with the LUK kit, I'd advise on getting a better release bearing. The one in the kit has a weird wobble design and mine seems to briefly squeal really loud at high RPM shifts. I also replaced the shift fork pivot pin. I used a brass pin, but forgot to lubricate it. I get an annoying squeak with every press of the clutch pedal and it's super annoying. If I could go back, I would just replace that part with the stock nylon pivot. Other than those 2 issues, everything seems pretty solid and grippy.

[Uturn540]

Ordered parts today, including a Luk 03042 kit and some assorted parts from ECS. Going to take a good look at the LUK throwout bearing, if it is not acceptable I will be ordering a Sachs unit. It is a shame that sometimes you have to piecemeal it!

[777300ER]

Don't mean to threadjack, But can the e34 M5 clutch be used with a single mass flywheel of does that not work? I wanted to replace my dual mass with failing SAC with a non SAC option and I am not a fan of UUC.

[computiNATEor]

Don't mean to threadjack, But can the e34 M5 clutch be used with a single mass flywheel of does that not work? I wanted to replace my dual mass with failing SAC with a non SAC option and I am not a fan of UUC.

ECS Tuning sells a single-mass flywheel for the I6 E39s; not sure about the 540.

[geargrinder]

I've never heard of the E34 setup being fit to an E39 but its crossed my mind if it would work (and you'd think it might unless the crank triggers and sensors are different... that might be the killer..)

For OP yeah just go factory M5. I've heard the Sachs and Luk are made in the same factory - they look pretty identical to me although some listers claim to have looked at them side by side and seen a tiny difference in the Sachs looking slightly better. However I know a ton of people who've done the M5 Luk (including me, before I went SouthBend then Spec) with zero problems.

TripleSev I'll answer your question in your thread...

[Uturn540]

Well the parts came in early and I felt rambunctious. I have come to the conclusion that anyone who says a clutch change in a 540i is a pain needs to sell their wrenches. Five hours start to finish running solo. Included dressing the flywheel, installing the CDV, and using the torque wrench judiciously. Worst part is reinstalling the exhaust system by myself with the car six feet in the air. That said, the Jeep Wrangler took ten hours with two of us wrenching. Clutch start.jpg

[geargrinder]

Nice. Only thing I'd say is... havin a lift and a couple exhaust jacks... Hell I'd be changing clutches every day and twice on Sundays if I had that setup!

[waters17]

I have come to the conclusion that anyone who says a clutch change in a 540i is a pain needs to sell their wrenches.

Says the guy with the lift... ಠ_ಠ


I think I spent a good hour+ just trying to get the car 2ft off the ground with jack stands. I didn't even have a creeper to slide around on. That being said, it was fairly straight forward.

[Uturn540]

I have done my share on the ground using ramps, jack stands and a ATV jack. That is why I have the lift now. With the labor rates the dealer charges, what I saved on the clutch job is about what I payed for the lift. But then again, having a lift you actually end up doing a lot more clutch changes among other things.

[JimLev]

But then again, having a lift you actually end up doing a lot more clutch changes among other things.

You sure do, for all your friends and the ones that want to be your friends too.

[computiNATEor]

I have done my share on the ground using ramps, jack stands and a ATV jack. That is why I have the lift now. With the labor rates the dealer charges, what I saved on the clutch job is about what I payed for the lift. But then again, having a lift you actually end up doing a lot more clutch changes among other things.

How much beer per hour of lift time do you charge? Or your poison of choice?

[Uturn540]

You sure do, for all your friends and the ones that want to be your friends too.

Exactly. If I am lucky I can even get them to do some of the work.

- - - Updated - - -

How much beer per hour of lift time do you charge? Or your poison of choice?

Close friends, family, and enthusiasts are always welcome. Occasionally there is the charity job for someone cannot afford the local rates, but is at least willing to try to do the upkeep. Slackers need not apply!

[wfseward96]

Nice. Only thing I'd say is... havin a lift and a couple exhaust jacks... Hell I'd be changing clutches every day and twice on Sundays if I had that setup!

+1 on that. I just finished torquing the flywheel and clutch in place last night, with super stiff neck today (Ok that could be somewhat age related). Now I am bracing for the struggle to slide the trans under the car and try and slide/muscle it on the harbor fraught scissor trans jack under the car. Not enough clearance to put on the jack and slide under.

Simple tasks with a lift become gymnastic endurance tests under floor jacks. I envy anyone with lift available. I'd seriously consider investing in one if my garage was tall enough. Only upside to doing the hard way is I've lost some pounds

[JimLev]

Wfse, I have the HF scissor tranny jack too.
Take the front pass side wheel off, then roll the tranny on the jack under the car with the bellhousing part going thru the wheel opening.
Worked for me.

[waters17]

Wfse, I have the HF scissor tranny jack too.
Take the front pass side wheel off, then roll the tranny on the jack under the car with the bellhousing part going thru the wheel opening.
Worked for me.

I think I mimicked your way when I did mine. Same HF trans jack, same bottle jack stands. I got the car about 22" off the ground and was able to remove the trans without removing the wheel or even turning them.. There was a very little window that allowed the trans to slip out, but doable with the wheels still on the car.

[wfseward96]

Wfse, I have the HF scissor tranny jack too.
Take the front pass side wheel off, then roll the tranny on the jack under the car with the bellhousing part going thru the wheel opening.
Worked for me.

Dang that trick could save me some strain.Ill give it a try. Thanks!

[wfseward96]

I think I mimicked your way when I did mine. Same HF trans jack, same bottle jack stands. I got the car about 22" off the ground and was able to remove the trans without removing the wheel or even turning them.. There was a very little window that allowed the trans to slip out, but doable with the wheels still on the car.

Well I didn't have enough room on the passengers side due to car location, but in looking at the new 6 ton HF jacks I got for all the work I'm doing, I realized I could temporarily jack the front up high enough to get under with trans on jack.
IMG_7768.jpg


And there she is, like the shuttle ready to dock to the space station. (sorry about the image rotation)

[philly98540]

Last go round, I just heaved the tranny up into position. Was a bit heavy dragging it onto my stomach, but went up without too much hassle and saved some time.

[geargrinder]

Last go round, I just heaved the tranny up into position. Was a bit heavy dragging it onto my stomach, but went up without too much hassle and saved some time.

'
Philly training for his next clutch swap.

[JimLev]

And I thought it was all those 12 and 16 oz. curls.

[philly98540]

Lol!

[sleuth255]

Last go round, I just heaved the tranny up into position. Was a bit heavy dragging it onto my stomach, but went up without too much hassle and saved some time.

I benched the tranny back into my pinto in '79. It was one of those 'never again' moments in my life. Who knows, maybe an E39 tranny is lighter.