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Thread: E39 540 Self Adjusting Clutch Question

  1. #1
    Join Date
    May 2012
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    Georgia
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    83 Mercedes 300D,87 325i

    E39 540 Self Adjusting Clutch Question

    Hi guys, wanted to make a quick post to ask about the self adjusting clutch kits on these 540s.

    I bought a clutch kit but it did not come with the "locking mechanism" that comes on the pressure plate fingers. Is there a way I can " adjust " this so that it can be " adjusted". Or can someone explain how this actually works? Just looking for some info here as I DO NOT want to do this job twice.

    Thanks for your time. I shall be posting pictures of what I'm talking about soon.
    97 528i 5 Speed | 290K+ and counting | Amber LED tails | Always broken | Eibach Sways | Crap Coilovers |

  2. #2
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    At this point it's considered a used pressure plate. And yes they can be reset, but you need something to press on the pressure plate springs, and rotate the inner "wedge" plate against the wegde plate springs, tightening it again. After rotating to reset to original, you need to lock the self adjusting mechanism.


    I have done this using a lathe to hold the pressure plate and the tailstock to press onto the pressure plate while I reset it and locked it.
    -Abel

    - E36 328is ~210-220whp: Lots of Mods.
    - 2000 Z3: Many Mods.
    - 2003 VW Jetta TDI Manual 47-50mpg
    - 1999 S52 Estoril M Coupe
    - 2014 328d Wagon, self-tuned, 270hp/430ft-lbs
    - 2019 M2 Competition, self-tuned, 504whp
    - 2016 Mini Cooper S

  3. #3
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    Chris (Bmwdirtracer) also has found a secret method to reset the self adjusting though I'm not sure if it's the same one as Abel's (328 power 04) they are both amazing techs
    C217 S63 AMG S Cabriolet ( Daily )

    E87 116i with mild cams, headers, cold air intake making 136 bhp Lol (My Learning Track Car)

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  4. #4
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    Here are some pictures.
    and just to clarify, i did receive this kit new. It came in enclosed packaging.1072-09068356-1052866.jpg27999141_10155165111402466_1340115023_o.jpg
    Attached Images Attached Images
    97 528i 5 Speed | 290K+ and counting | Amber LED tails | Always broken | Eibach Sways | Crap Coilovers |

  5. #5
    Join Date
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    36 Cylinders
    27999141_10155165111402466_1340115023_ed.jpg


    This is roughly how I did it.
    It takes some creativity.



    Upon a light Google search, some of these clutches do not come locked, and require the installer to set them in on car with a special tool. My method would still work if you install it 'locked'.


    This should explain everything
    superb-1222.png
    Last edited by 328 Power 04; 02-16-2018 at 05:39 PM.
    -Abel

    - E36 328is ~210-220whp: Lots of Mods.
    - 2000 Z3: Many Mods.
    - 2003 VW Jetta TDI Manual 47-50mpg
    - 1999 S52 Estoril M Coupe
    - 2014 328d Wagon, self-tuned, 270hp/430ft-lbs
    - 2019 M2 Competition, self-tuned, 504whp
    - 2016 Mini Cooper S

  6. #6
    Join Date
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    I'd send it back, and demand that the company send you a functional one with the damned lock! That is absolute nonsense. Officially, if the lock is released, the clutch is garbage, and cannot even be returned. You've been cheated, and sold a P.O.S.

    Sure, I've had to cheat, and re-use a clutch which had been unlocked ... but it came locked, and I had the locking star to re-lock it.

    Chris Powell
    Racer and Instructor since, well. decades, ok?
    Master Auto Tech, owner of German Motors of Aberdeen
    BMWCCA 274412
    German Motors is hiring ! https://www.bimmerforums.com/forum/s...1#post30831471

  7. #7
    Join Date
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    Thank you guys for the help! It is really appreciated. I posted here in efforts to find a solution of what they gave me. While it can be done to "adjust" the clutch back, I think it is best I just tell the company to send me another one so I can get this show on the road with out this fuss. I was not in a rush to get the clutch done but would have liked the convince of it on hand if I decided i was going to do it. I guess ill just have to wait.

    The car needs other things for now like passing emissions! I need it to do that first so i can get it registered etc. Talking to a friend, he was saying we should just get the motor out and reseal and put timing chain guides on it anyway just to get it all out of the way. The car has 155k and I haven't heard any chain issues yet( which is surprising to me) .

    The other thing on the list is to get the car painted as the paint has suffered an extreme clear coat failure. and a few other cosmetic stuff.

    Thanks once again!
    97 528i 5 Speed | 290K+ and counting | Amber LED tails | Always broken | Eibach Sways | Crap Coilovers |

  8. #8
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    Just to update everyone on this.....i ended up sending the other clutch kit back and ordering another. What do you know......the clutch kit came the EXACT SAME WAY! From the looks, this is how they came from the manufacturer. I'm guessing what they intended was that you have the proper tool in order to set the clutch properly. So for now I will have to deal with it and work with what I got. I will take the suggestions mentioned above and have to reset the clutch myself.
    97 528i 5 Speed | 290K+ and counting | Amber LED tails | Always broken | Eibach Sways | Crap Coilovers |

  9. #9
    Join Date
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    E39M5, E500 4WD
    Your very first photo shows the way a self-adjusting clutch should arrive. You install it, and then you remove the lock.

    Please post the name of the place you bought this nonsense, and the manufacturer, so we can all avoid similar crap.

    Chris Powell
    Racer and Instructor since, well. decades, ok?
    Master Auto Tech, owner of German Motors of Aberdeen
    BMWCCA 274412
    German Motors is hiring ! https://www.bimmerforums.com/forum/s...1#post30831471

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