2008 MINI Cooper

2007 TRANSMISSION Clutch - Repair Instructions - Cooper

2007 TRANSMISSION

Clutch - Repair Instructions - Cooper

00 MAINTENANCE AND INSPECTION

21 00 006 BLEEDING CLUTCH HYDRAULIC SYSTEM

Necessary preliminary tasks:

Connect bleeder unit to brake fluid expansion tank.

IMPORTANT: Check relevant Operating Instructions for each device.

Charging pressure should not exceed 2 bar.

Remove dust cap from bleed valve.

Connect bleeder hose to bleed valve (1).

Fig. 1: Bleed Valve

Courtesy of BMW OF NORTH AMERICA, INC.

Open bleed valve (1) and flush until clear brake fluid emerges without air bubbles.

Close bleed valve.

Switch off bleeder unit or remove from expansion tank.

Correct brake fluid level in expansion tank.

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2007 TRANSMISSION Clutch - Repair Instructions - Cooper

Fig. 2: Opening Bleed Valve

Courtesy of BMW OF NORTH AMERICA, INC.

21 CLUTCH WITH DRIVING DISC

21 21 500 REMOVING AND INSTALLING OR REPLACING CLUTCH

Special tools required:

11 9 590 PLUG MANDREL

21 2 290 CLUTCH CENTERING TOOL
21 6 110

Necessary preliminary tasks:

Remove transmission, see 23 00 026 REMOVING AND INSTALLING TRANSMISSION (GS6-55BG) .

Lock flywheel with special tool 11 9 590 .

Fig. 3: Special Tools (11 9 590)

Courtesy of BMW OF NORTH AMERICA, INC.

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 2008 MINI Cooper
2007 TRANSMISSION Clutch - Repair Instructions - Cooper

Slacken bolts uniformly.

Unscrew bolts.

Remove pressure plate and clutch plate.

Clean flywheel and check for wear and damage.

If necessary, replace flywheel, see 11 22 500 REMOVING AND INSTALLING OR REPLACING

FLYWHEEL (N12) .

Fig. 4: Locating Bolts

Courtesy of BMW OF NORTH AMERICA, INC.

Check clutch plate for damage and friction rust, replace if necessary.

Replace contaminated clutch plate (oil, cleaning agent etc.).

NOTE: Direction marking GEARBOX SIDE (1) for transmission side of clutch plate.

Fig. 5: Mark On Gearbox Side For Transmission Side Of Clutch Plate

Courtesy of BMW OF NORTH AMERICA, INC.

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 2008 MINI Cooper
2007 TRANSMISSION Clutch - Repair Instructions - Cooper

Check clutch disk for wear.

Measure lining protrusion on transmission side.

Measure from rivet head (1).

The clutch plate must be replaced if the lining clearance at the rivet head (1) is less than 1 mm.

Fig. 6: Measuring Lining Protrusion On Transmission Side

Courtesy of BMW OF NORTH AMERICA, INC.

Install pressure plate and clutch plate with special tool.

N12 with GS655BG: 21 2 290

N14 with GS653BG: 21 6 110

Fig. 7: Special Tools (21 2 290)

Courtesy of BMW OF NORTH AMERICA, INC.

Replace bolts of pressure plate and tighten down in sequence (1-6).

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 2008 MINI Cooper
2007 TRANSMISSION Clutch - Repair Instructions - Cooper

Installation:

Turn centering mandrel 21 2 290 outwards in stages when tightening down pressure plate. Pressure plates must
not touch centering mandrel.

Tightening torque: 21 21 4AZ, see 21 21 CLUTCH PLATE AND DRIVE PLATE .

Fig. 8: Tightening Sequence Of Bolts

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Turn special tool 21 2 290 when tightening down the pressure plate in order to
center the clutch plate better.
Remove special tool 11 9 590 .
Remove special tool 21 6 110.

51 CLUTCH RELEASE CONTROLLER W/ LEVER

21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE UNIT

Necessary preliminary tasks:

Transmission removed, see 23 00 026 REMOVING AND INSTALLING TRANSMISSION (GS6-

55BG)

When installing a new clutch, you must also replace the release bearing.

Press spring wire clip (1) through clutch release lever (2).

Remove clutch release lever (2).

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 2008 MINI Cooper
2007 TRANSMISSION Clutch - Repair Instructions - Cooper

Fig. 9: Spring Wire Clip And Clutch Release Lever

Courtesy of BMW OF NORTH AMERICA, INC.

Press in retainers (1) slightly and remove clutch release bearing.

Installation:

Clean all sliding surfaces on clutch release bearing.

Check for damage and replace if necessary.

Do not grease clutch release lever.

Fig. 10: Retainers

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Check spring wire clip (1) and ball pin (2) for damage and replace if necessary.

Remove spring wire clip (1).

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2007 TRANSMISSION Clutch - Repair Instructions - Cooper

Lightly grease ball pin (2).

Clean sliding surface of guide sleeve (3).

Fig. 11: Spring Wire Clip, Ball Pin And Guide Sleeve
Courtesy of BMW OF NORTH AMERICA, INC.

Install spring wire clip (1) in release lever (2).

Install clutch release lever.

Fig. 12: Spring Wire Clip And Release Lever

Courtesy of BMW OF NORTH AMERICA, INC.

52 CLUTCH OPERATION (HYDRAULIC)

21 52 010 REMOVING AND INSTALLING OR REPLACING CLUTCH SLAVE CYLINDER

NOTE: After completing work bleed clutch hydraulic system, see 21 00 006 Bleeding
clutch hydraulic system.

Draw off brake fluid until level is below connection to clutch master cylinder.

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2007 TRANSMISSION Clutch - Repair Instructions - Cooper

Fig. 13: Drawing Off Brake Fluid

Courtesy of BMW OF NORTH AMERICA, INC.

Release nuts (1) of clutch slave cylinder.

Remove clutch slave cylinder (2).

Release line connection (3) and disconnect line (4).

Tightening torque: 21 52 2AZ, see 21 52 CLUTCH CONTROL (HYDRAULIC) .

IMPORTANT: Catch escaping brake fluid in a suitable container.

Fig. 14: Nuts, Clutch Slave Cylinder, Line Connection And Line
Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Clean thrust member (1) and contact face on release lever (2).

Lightly grease thrust member (1) on contact face (3).

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2007 TRANSMISSION Clutch - Repair Instructions - Cooper

Fig. 15: Thrust Member, Release Lever And Contact Face

Courtesy of BMW OF NORTH AMERICA, INC.

21 52 500 REMOVING AND INSTALLING OR REPLACING CLUTCH MASTER CYLINDER

Necessary preliminary tasks:

Remove bearing block for foot pedal, see 35 11 000 REMOVING AND INSTALLING COMPLETE
BEARING BLOCK FOR FOOT PEDAL

Press pin (1) together and press out.

Release nuts (2) and remove clutch master cylinder.

Tightening torque: 21 52 3AZ, see 21 52 CLUTCH CONTROL (HYDRAULIC) .

IMPORTANT: After completing tasks

Bleed clutch hydraulic system, see 21 00 006 Bleeding clutch hydraulic system.

Fig. 16: Pin And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Monday, June 25, 2012 9:19:40 AM Page 9 © 2011 Mitchell Repair Information Company, LLC.