Recommended replacement interval for the part category Clutch kit : 100000 km

Important!

This replacement procedure can be used for:
BMW 5 Saloon (E60) 520 i, BMW 5 Saloon (E60) 525 i … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Clutch Kit for 5 Saloon (E60) and other BMW models

Clutch kit

Clutch kit for BMW 5 Saloon (E60) 520 i Petrol (170 hp)

Simple DIY car repair steps – Replacing Clutch kit on BMW 5 Saloon (E60) 525 i

Clutch kit for BMW 5 Saloon (E60) 525 i Petrol (192 hp)

Replacement: clutch kit – BMW 5 (E60). Tools you might need:

                        Wire brush
                      
                        WD-40 spray
                      
                        All-purpose cleaning spray
                      
                        Multipurpose grease
                      
                        Torque wrench
                      
                        Combination spanner #13
                      
                        Combination spanner #18
                      
                        Drive socket # 10 
                      
                        Drive socket # 13 
                      
                        Drive socket # 16 
                      
                        Drive socket # 18 
                      
                        Torx bit E11
                      
                        Torx bit E12
                      
                        Torx bit E14
                      
                        HEX bit No.H6
                      
                        HEX bit No.H14
                      
                        Ratchet wrench
                      
                        Phillips Screwdriver
                      
                        Clutch tool kit
                      
                        Crow bar
                      
                        Hydraulic transmission jack
                      
                        Fender cover

Buy tools

Replacement: clutch kit – BMW 5 (E60). AUTODOC experts recommend:

Replace the entire clutch kit assembly: the pressure plate, clutch disc, and release bearing.
Please note: all work on the car – BMW 5 (E60) – should be done with the engine switched off.

Carry out replacement in the following order:

Step 1

Open the bonnet.

Step 2

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.

Step 3

Open the boot lid.

Step 4

Remove the battery cover.
Step 5

Unscrew the negative battery terminal fastener. Use a drive socket #10. Use a ratchet wrench.
Step 6

Disconnect the earth cable terminal from the battery.
Step 7

Lift the car using a jack or place it over an inspection pit.

Step 8

Unscrew the engine splash guard fasteners. Use a Phillips screwdriver.
Step 9

Remove the engine splash guard.
Step 10

Prop up the subframe reinforcement bracket. Use a hydraulic transmission jack.
Step 11

Unscrew the subframe reinforcement bracket fasteners. Use a drive socket #16. Use a ratchet wrench.
Step 12

Remove the subframe bracket.

Replacement: clutch kit – BMW 5 (E60). Tip from AUTODOC experts:
Make marks on the front propshaft coupling to indicate its position.
Step 13

Unscrew the propshaft coupling fasteners. Use a combination spanner #18. Use a drive socket #18. Use a ratchet wrench.
Step 14

Unscrew the clutch slave cylinder fasteners. Use a drive socket #13. Use a ratchet wrench.
Step 15

Remove the clutch slave cylinder.
Step 16

Disconnect the transmission sensor connector.
Step 17

Prop up the gearbox support. Use a hydraulic transmission jack.
Step 18

Unscrew the fasteners that connect the gearbox support to the car body. Use a drive socket #13. Use a ratchet wrench.
Step 19

Unsnap the locking pin on the shift lever support arm. Use a crowbar.
Step 20

Remove the cotter pin.

Step 21

Disconnect the shift lever support arm.
Step 22

Remove the selector rod retaining clip.
Step 23

Detach the selector rod.
Step 24

Clean the exhaust system fastener. Use a wire brush. Use WD-40 spray.
Step 25

Unscrew the exhaust system fasteners. Use a combination spanner #13. Use a drive socket #13. Use a ratchet wrench.
Step 26

Remove the exhaust system fastener.
Step 27

Unscrew the exhaust system bracket fasteners from the car body. Use a drive socket #13. Use a ratchet wrench.
Step 28

Remove the exhaust system bracket.

Step 29

Use a metal hook to hang the exhaust line to the suspension components or to the car body.
Step 30

Unscrew the fasteners of the exhaust heat shield. Use a drive socket #10. Use a ratchet wrench.
Step 31

Remove the exhaust heat shield.
Step 32

Unscrew the fasteners of the propeller shaft centre support bearing. Use a drive socket #13. Use a ratchet wrench.
Step 33

Disconnect the propshaft centre bearing from the car body.
Step 34

Move the propeller shaft aside.

Replacement: clutch kit – BMW 5 (E60). Tip from AUTODOC:
Secure the propeller shaft to the car body to prevent injuries.
Step 35

Remove the propshaft coupling.
Step 36

Unscrew the lower fasteners that connect the gearbox to the engine. Use Torx E11. Use a ratchet wrench.
Step 37

Remove the fastening bolts.
Step 38

Unscrew the engine starter fasteners. Use Torx E12. Use a ratchet wrench.
Step 39

Move the starter away from the gearbox.
Step 40

Unscrew the fasteners that connect the gearbox to the engine block. Use Torx E14. Use a ratchet wrench.
Step 41

Remove the fastening bolts.
Step 42

Disconnect the gearbox from the engine. Use a crowbar.
Step 43

Remove the gearbox. Use a hydraulic transmission jack.
Step 44

Install the engine flywheel locking tool. Use a clutch tool kit.
Step 45

Unscrew the pressure plate fasteners. Use HEX No.H6. Use a ratchet wrench.
Step 46

Remove the fastening bolts.
Step 47

Remove the pressure plate together with the clutch disc. Use a crowbar.
Step 48

Clean the clutch kit mounting seats. Use all-purpose cleaning spray.
Step 49

Install the new pressure plate together with the clutch disc.
Step 50

Align the clutch disc. Use a clutch tool kit.

Replacement: clutch kit – BMW 5 (E60). Tip from AUTODOC experts:
Be careful not to damage the part.
Step 51

Install the fastening bolts.
Step 52

Screw in the pressure plate fasteners. Use HEX No.H6. Use a ratchet wrench.

Step 53

Tighten the pressure plate fasteners. Use HEX No.H6. Use a torque wrench. Tighten it to 25 Nm torque.
Step 54

Unscrew the locking plate of the pressure plate. Use HEX No.H14. Use a ratchet wrench.

Replacement: clutch kit – BMW 5 (E60). Tip:
When unscrewing it, the clutch diaphragm spring may click.
Step 55

Remove the flywheel locking tool.
Step 56

Remove the release bearing.
Step 57

Remove the clutch release fork lever.
Step 58

Clean the clutch release bearing mounting seat. Use all-purpose cleaning spray.
Step 59

Treat the release bearing mounting seat. Use a multipurpose grease.
Step 60

Install the clutch release fork lever.
Step 61

Install the new release bearing.
Step 62

Install the gearbox. Use a hydraulic transmission jack.

Replacement: clutch kit – BMW 5 (E60). AUTODOC experts recommend:
Take care to prevent the gearbox from being unsupported (hanging).
Step 63

Install the fastening bolts.
Step 64

Tighten the lower fasteners that connect the gearbox to the engine. Use Torx E11. Use a ratchet wrench.

Step 65

Install the engine starter.
Step 66

Screw in the engine starter fasteners. Use Torx E12. Use a ratchet wrench.
Step 67

Install the fastening bolts.
Step 68

Screw in the fasteners that connect the gearbox to the engine block. Use Torx E14. Use a ratchet wrench.

Step 69

Tighten the engine starter fasteners. Use Torx E12. Use a torque wrench. Tighten it to 43 Nm torque.
Step 70

Tighten the fasteners that connect the gearbox to the engine block. Use Torx E14. Use a torque wrench. Tighten it to 72 Nm torque.
Step 71

Tighten the lower fasteners that connect the gearbox to the engine. Use Torx E11. Use a torque wrench. Tighten it to 22 Nm torque.
Step 72

Attach the shift lever support arm.
Step 73

Install the cotter pin.
Step 74

Secure the locking pin on the shift lever support arm.
Step 75

Attach the selector rod.
Step 76

Attach the selector rod retaining clip.
Step 77

Connect the propeller shaft to the gearbox flange via the propshaft coupling.
Step 78

Align the propeller shaft flange with the mark you made.
Step 79

Tighten the propshaft coupling fasteners. Use a combination spanner #18. Use a drive socket #18. Use a torque wrench. Tighten it to 100 Nm torque.
Step 80

Attach the propshaft centre bearing to the car body.
Step 81

Tighten the fasteners of the propeller shaft centre support bearing. Use a drive socket #13. Use a torque wrench. Tighten it to 32 Nm torque.
Step 82

Prop up the gearbox support. Use a hydraulic transmission jack.
Step 83

Tighten the fasteners that connect the gearbox support to the car body. Use a drive socket #13. Use a torque wrench. Tighten it to 35 Nm torque.
Step 84

Prop up the exhaust line. Use a hydraulic transmission jack.
Step 85

Install the exhaust heat shield.
Step 86

Tighten the fasteners of the exhaust heat shield. Use a drive socket #10. Use a ratchet wrench.
Step 87

Install the exhaust system fastener.
Step 88

Tighten the exhaust system fasteners. Use a drive socket #13. Use a torque wrench. Tighten it to 22 Nm torque.
Step 89

Install the exhaust system bracket.
Step 90

Tighten the fasteners that connect the exhaust system bracket to the car body. Use a drive socket #13. Use a torque wrench. Tighten it to 22 Nm torque.
Step 91

Attach the transmission sensor connector.
Step 92

Install the clutch slave cylinder.
Step 93

Tighten the clutch slave cylinder fasteners. Use a drive socket #13. Use a torque wrench. Tighten it to 22 Nm torque.
Step 94

Install the subframe bracket.
Step 95

Tighten the subframe reinforcement bracket fasteners. Use a drive socket #16. Use a torque wrench. Tighten it to 59 Nm torque. +90°
Step 96

Install the engine splash guard.
Step 97

Tighten the engine splash guard fasteners. Use a Phillips screwdriver.
Step 98

Lower the car.

Step 99

Connect the earth cable terminal to the battery.
Step 100

Screw in the negative battery terminal fastener. Use a drive socket #10. Use a ratchet wrench.
Step 101

Install the battery cover.

Step 102

Close the lid of the luggage compartment.

Step 103

Run the engine for a few minutes. This is necessary in order to make sure that the component operates properly.

Step 104

Shut off the engine.

Step 105

Remove the fender protection cover.

Step 106

Close the hood.

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