BMW E90 3-Series Clutch Replacement

The BMW clutch is activated using hydraulics. The clutch hydraulic components consist of a master cylinder at the clutch pedal and a slave cylinder at the transmission bellhousing. Fluid from the brake fluid reservoir is shared with the clutch system. Depressing the clutch pedal forces fluid in the clutch master cylinder to travel through the fluid line to the clutch slave cylinder. This activates the clutch release lever, forcing the clutch release bearing against the clutch pressure plate to disengage the clutch.

Keep in mind the following:

If brake fluid is lost for any reason and the level in the brake fluid reservoir drops below the level of the clutch master cylinder shunt hose, clutch hydraulic failure may follow.

Clutch hydraulic failure causes a softness in the clutch pedal. The lack of resistance means that the clutch is not becoming fully disengaged when the pedal is depressed to the floor. As a result, gear shifting becomes difficult; the transmission gears clash and grind during shifts. Damage to transmission synchronizers and gears will result.

If experiencing grinding gears and difficult shifting:

Check brake fluid reservoir level. Top off if necessary.

Check clutch fluid lines for leakage. Repair as necessary.

Check clutch master cylinder for leakage. Replace if necessary.

Check clutch slave cylinder for leakage. Replace if necessary.

Bleed clutch system.

Failure Summary

Faulty transmission of power to the wheel is caused by a worn out clutch. If the engine revs up without a corresponding increase in vehicle speed, clutch mechanical components are at fault.

Grinding gears when shifting, or difficult shifting up or down the gears, is caused by a failure in clutch hydraulics.

Clutch Replacing

Have a new clutch kit and new transmission bolts on hand before beginning. Always replace aluminum bolts. See our tech article on non-reusable fasteners. Read through procedure to be sure you have all the tools required and the job is not beyond your skill set.

Jack up your vehicle and support using jack stands. See our tech article on jacking up your vehicle. :https://www.pelicanparts.com/BMW/techarticles/BMW-3-Series-E90/BASICS-Jacking_Up_Your_Vehicle/BASICS-Jacking_Up_Your_Vehicle.htm

Remove transmission splash shields. See our tech article on engine splash shields removing. :https://www.pelicanparts.com/BMW/techarticles/BMW-3-Series-E90/BASICS-Engine_Transmission_Splash_Shield_Removing/BASICS-Engine_Transmission_Splash_Shield_Removing.htm

Read the Full Article: https://www.pelicanparts.com/BMW/techarticles/BMW-3-Series-E90/TRANS-Clutch_Replacing/TRANS-Clutch_Replacing.htm

Time: 9 hours
Tools: Socket set :https://www.pelicanparts.com/BMW/catalog/tools/sockets-ratchets-drive.htm, transmission jack :https://www.pelicanparts.com/BMW/catalog/Tools/jacks.htm, Inverted Torx sockets, E10, E12, E14, :https://www.pelicanparts.com/BMW/catalog/tools/sockets-ratchets-drive.htm
Parts Required: Clutch kit, transmission bolts
Hot Tip: Set aside a day and read procedure through before beginning
Performance Gain: New clutch :https://www.pelicanparts.com/cgi-bin/supertech/catalog.cgi?action=frameset&return-url=/cgi-bin/supertech/catalog.cgi%3Faction%3Dframeback%26page%3D1205&catalog-url=https%3A%2F%2Fwww.pelicanparts.com%2Fcatalog%2FSuperCat%2F4139%2FBMW_4139_TCLUTC_pg1.htm%23item1
Complementary Modification: Replace driveshaft flex-disc
Applicable Models:
BMW 325i Sedan (2006)
BMW 328i Coupe (2007-13)
BMW 328i Sedan (2007-11)
BMW 328i Wagon (2007-12)
BMW 328i xDrive Coupe (2009-13)
BMW 328i xDrive Sedan (2009-11) :https://www.pelicanparts.com/catalog/SuperCat/BE90_catalog.htm

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