e46 Clutch Help

[JSalzl]

As some of you know, I've been driving a 2002 325i for about a year and a half and the clutch has been on its way out for about the last six months. It's getting pretty bad and the time has come where i'm going to have to break down and spend the money. I've been calling around getting quotes from Eurotech, Motorwerks and a couple of other shops and I'm not liking the numbers i'm hearing. It's hard to justify spending almost a third the cost of the car to have a clutch done by someone else. I have the tools and I probably could do it myself, but I would need to have all the parts and be able to crank it out in one weekend or less as I do not have a access to a spare vehicle.

Everyone I call keeps telling me that I'm going to need a new flywheel which is the most expensive part of this whole job hands down, more than labor even. This doesn't seem to be the case from stories I've read on the internet, in most of those cases the old flywheel is usually okay. Can any E46 owners chime in on whether you needed the flywheel?


Also if i do end up tackling this myself on a garage floor, what do i need as far as things to purchase? I've never done a clutch before, but i'm sure i can figure it out.

clutch
clutch alignment tool
flywheel?
slave cylinder?
pressure plate bolts
pilot bearing
throwout bearing?
various gaskets and seals?

Any input would be greatly appreciated!

[JTapper]

Guibo's are cheap. Might as well replace it while you're in there.

[JSalzl]

Also does anyone have a e46 bentley manual I can rent or borrow and put a deposit on?

[Tom.W]

http://www.bavauto.com/ has kits with the flywheel for under 900

I received a flywheel in the cheaper kit that was questionable, the stage 2 or the kit with the ucc flywheel may be a better option.


If the clutch has been slipping for a long time, chances are the flywheel will need to be replaced.

[JSalzl]

okay well thats good to know i'm regretting not having done it a long time ago now i didn't realize you couldn't just turn the flywheel...

What is the downfall to running a single mass flywheel?

[BMW]

My audi had a dual mass, I'm pretty sure its just for noise and ease of driving. The single mass will feel more touchy. The thing to keep in mind is that the "bushing" for lack of a better word, between the two seperate flywheel discs does wear out, and is also to why they are so expensive. I would get an aftermarket kit with a single mass, plus they include all the little odds and ends like the throw out bearing n stuff.

I have done the clutch package on an e36, and my b5 a4, and the bmw was easier. Just find a good diy article online and make sure you give yourself enough space under the car. Its not fun though without a lift, but doable.

[JSalzl]

Well after researching parts, I found I can get a single mass UCC flywheel with a e34 m5 clutch for about about $1000 or i can get an oem style dual mass with a oem clutch for about $1000. I have no power adders of any kind, but I do on occasion drive in a "spirited" nature. What are the costs an benefits to going either way?

[BMW]

I had a similar UUC package on my e36 and loved it. An aftermarket clutch may not last as long but that's with any performance upgrade usually.

[2.5-12]

you can also convert to any 6 pot E36 flywheel/clutch/PP TOB and release bearing combo. they're cheaper and they fit (same Getrag 250 trans). I run a 92' 325iS dual mass clutch, PP, and even trans in my E46.(this only applies to E46s with the 10 tooth input shaft, not the 21 tooth cars). check realoem for your build code to see if this is an option.

if you do it on your floor, borrow a transmission jack, have another person for trans fitting.

have 30+" 3/8 extensions, a u joint (NOT a wobble joint, too thick). inverse Etorx sockets and a ratchet strap to pull the motor back (to keep it tilted back for trans install). if you buy a new slave cyl, do the master cyl at the same time, but not worth doing unless you feel it needs it (not hard to go after the fact at all).

buy new exhaust flange gaskets and hardware. this is worth getting OEM, oreilly gaskets are slightly too large and while they do work, its annoying to make the very minimal modification.

other than that, do the guibo if it shows any sign of wear. freshen up your bushings on the selector rod if they're in bad nick. check the front and rear seals on the trans as its like $20 for both and easy as pie to do when the trans it out.

other than those things, basic stuff comes with a clutch kit, new PP bolts are a must. clutch allignment tool is a huge must and a time saver (manually aligning is hard and very time consuming).

be sure you have at least 15" of clearance between the car and the ground for trans removal.

[JTapper]

You can turn that dual-mass one if you take it to the right place.

Headwerks in Bloomington can turn them. He has a special fixture to hold them correctly. IIRC, I paid $125 to have the Audi one turned.

[JSalzl]

^ Good to know!

I definitely need to tighten up my shifter its pretty bad, but As far as shifter bushings go are the poly bushings like these the only ones i need to worry about?

[2.5-12]

theres a bushing in the actual selector cup on the trans linkage, those you pictured are a good idea, the 4 yellow washers and the plastic cup that holds the selector rod.

[JSalzl]

I ended up finding a guy who would do it and let me help. I guess my definition of a horrible clutch slippage is different than most peoples, so my being anal saved me a bunch of money because I ended up not needing a new flywheel. Having a new clutch and a rebuilt shifter is fantastic. Thanks for the help