Clutch and Flywheel Replacement DIY | BMW E39 540i

Today I’m replacing the clutch on my 2000 BMW E39 540i fitted with the 6-speed manual transmission, and I'm showing you everything you need to know so you can replace the clutch on your E39 yourself. I've also included important information about removing the E39's flywheel if you're planning on replacing that as well. This is a challenging and time consuming DIY project that requires a lot of disassembly, but it's certainly not impossible as long as you have the space and proper tools (listed below).

TIME STAMPS:
Exhaust & Heat Shields - 0:21
Driveshaft - 01:44
Transmission Bell Housing - 02:43
Clutch & Pressure Plate - 05:40
Flywheel - 06:16
Torque Values - 07:41
DIY Summary - 09:59

PROCEDURE:
This procedure is for a BMW E39 540 fitted with the M62 V8 engine and 6-speed manual transmission. Overall, this is an involved repair that will most likely take around 8 hours to complete, but I'd recommend allocating an entire weekend so you don't rush. Parts ran me about $270, including the clutch kit and gasket that seals the CV joint and differential flange. BE CAREFUL WHEN REMOVING THE SLAVE CYLINDER AS THE RUBBER BOOT CAN TEAR AND FORCE YOU TO REPLACE IT.

PARTS:
1. Luk Clutch Kit - https://www.fcpeuro.com/products/bmw-clutch-kit-e39-luk-21217528209
2. CV Joint Gasket - https://www.fcpeuro.com/products/bmw-cv-joint-gasket-26111229504
3. Flywheel - I didn't replace my flywheel, but I recommend shopping around at shops like FCP Euro, ECS Tuning, Pelican Parts, etc. to find the best quality for your budget.

TOOLS:
There are a couple special tools that you need to be aware of and I've marked them with a * below. I go into more detail in the video, but I've included links to some of your options.

Exhaust + Heat Shield Tools:
- 13mm Socket
- 10mm Socket
- 8mm Socket

Driveshaft Tools:
- 16mm Wrench
- 21mm Socket
- 21mm Wrench
- 13mm Socket

Bell Housing Tools:
- Transmission Jack
- E12 Socket* (~$10): https://www.harborfreight.com/14-in-38-in-drive-impact-e-socket-set-7-pc-67898.html?cid=paid_google|||67898&utm_source=google&utm_medium=cpc&utm_campaign=&utm_content=&gclid=CjwKCAjwv4_1BRAhEiwAtMDLso20us7kBfMGAujfLdDXhQkJmnu-xg8Tt96bh1Kn-AyM6EmFugMbeBoCWekQAvD_BwE
- 16mm Wrench
- 13mm Socket
- 3+ ft of extensions
- Breaker Bar
- Swivel Joint (~$8): https://www.harborfreight.com/universal-joint-socket-adapter-set-3-pc-63141.html?cid=paid_google|||63141&utm_source=google&utm_medium=cpc&utm_campaign=&utm_content=&gclid=CjwKCAjwv4_1BRAhEiwAtMDLstIIani1v_oATx2u8_ZWDjUJOVRxja2-G4kmEn1y1Mmvzcoa4cBvcRoCt9AQAvD_BwE

Clutch / Pressure Plate Tools:
- 6mm Hex Head Socket* (~$8): https://www.harborfreight.com/38-in-drive-metric-hex-socket-set-6-pc-69546.html?cid=paid_google|||69546&utm_source=google&utm_medium=cpc&utm_campaign=&utm_content=&gclid=CjwKCAjw4pT1BRBUEiwAm5QuRw01VEVfZV0JzMy9gLNc4R_lTXigoBTkPs1zANVb_Y2r_NRKrjfTMxoChdUQAvD_BwE

Flywheel Tools:
- Special T60 Torx Socket* ($32) FCP Euro: https://www.fcpeuro.com/products/bmw-t60-flywheel-bolt-socket-cta-3759?ads_cmpid=1586640911&ads_adid=59893888775&ads_matchtype=&ads_network=g&ads_creative=298302526031&utm_term=&ads_targetid=pla-329388689743&utm_campaign=&utm_source=adwords&utm_medium=ppc&ttv=2&gclid=Cj0KCQjwka_1BRCPARIsAMlUmErZ25UjgdwWuI0PBMLC9pCsAqsoBjumGFwxjZ2dClcEMqm0r9I-35EaAlcFEALw_wcB#fitment
- Breaker Bar
- Flywheel Locking Tool (or improvise)* (~$57): https://www.fcpeuro.com/products/bmw-bracket-no-119260-83300493938?ads_cmpid=1586640911&ads_adid=59893888775&ads_matchtype=&ads_network=g&ads_creative=298302526031&utm_term=&ads_targetid=pla-327620319311&utm_campaign=&utm_source=adwords&utm_medium=ppc&ttv=2&gclid=Cj0KCQjwka_1BRCPARIsAMlUmErr83j6vIQicoiBZCVvVfGx1XbMFjEGxw0A73dSGXRJMLEQsF9j_4caAsjHEALw_wcB

Please leave a comment if you have any questions, thanks for watching!

Disclaimer:
Due to factors beyond the control of Tire Kickers, I cannot guarantee against improper use or unauthorized modifications of this information. Tire Kickers assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. Tire Kickers recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of Tire Kickers, no information contained in this video shall create any expressed or implied warranty or guarantee any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Tire Kickers.

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