BMW 328i Clutch Replacement DIY Part 1 (N52 Engine - 2006-2011 BMW E90, E91, E92 328xi, 328i xDrive)

Introduction

Replacing the clutch in a BMW 328i (N52 engine) is a significant but manageable task for those with mechanical skills. This tutorial outlines the step-by-step process for replacing the clutch in a 2006-2011 BMW E90, E91, or E92. By following these instructions, you can ensure your vehicle's performance and extend its lifespan.

Step 1: Gather Required Tools

Before starting the replacement process, gather all necessary tools and parts. Some essential items include:

• Jack and jack stands
• Torque wrench
• Socket set (including Torx and metric sizes)
• Screwdrivers
• Pliers
• Engine brace
• Transmission jack (optional but recommended)
• Replacement clutch kit and flywheel
• New rear main seal

Step 2: Set Up the Engine Brace

To safely support the engine while you work, follow these steps:

1. Position the engine brace: Place the engine brace securely across the engine bay.
2. Adjust the height: Ensure the brace is at the proper height to support the weight of the engine.

Step 3: Access the Underbody

To begin the disassembly, you need to access the undercarriage:

1. Raise the vehicle: Use a jack to lift the car and secure it with jack stands.
2. Remove the undercarriage covers: If applicable, take off any plastic or metal covers to expose the transmission and other components.

Step 4: Remove the Exhaust System

To gain better access to the transmission, you must remove the exhaust:

1. Unbolt the exhaust flanges: Use the appropriate socket to unfasten the bolts connecting the exhaust to the headers.
2. Detach the exhaust hangers: Carefully remove the exhaust hangers to free the exhaust system from the vehicle.

Step 5: Remove the Drive Shaft

Next, take out the drive shaft to fully disconnect the transmission:

1. Unbolt the drive shaft flanges: Remove the bolts connecting the drive shaft to the rear differential and transmission.
2. Slide the drive shaft out: Carefully maneuver the drive shaft out of the vehicle.

Step 6: Disconnect the Transmission

Now, it’s time to disconnect the transmission from the engine:

1. Remove the transmission bolts: Locate and unbolt the transmission bolts securing it to the engine.
2. Disconnect electrical connectors: Unplug any electrical connections attached to the transmission.

Step 7: Disconnect the Shifter

Before you can drop the transmission, the shifter must be disconnected:

1. Remove the shifter boot: Take off the boot covering the shifter in the interior.
2. Unbolt the shifter assembly: Remove the bolts and lift the shifter out of its housing.

Step 8: Drop the Transmission

With everything disconnected, you can now drop the transmission:

1. Use a transmission jack: Carefully lower the transmission from the vehicle.
2. Ensure safety: Make sure to have an extra pair of hands if necessary to avoid any accidents.

Step 9: Remove the Clutch and Flywheel

Once the transmission is out, you can replace the clutch:

1. Unbolt the flywheel: Remove the bolts securing the flywheel to the engine.
2. Take out the clutch disc: Carefully remove the clutch disc and pressure plate.

Step 10: Replace the Rear Main Seal

Before installing the new clutch, replace the rear main seal:

1. Remove the old seal: Carefully pry out the old rear main seal.
2. Install the new seal: Press in the new seal until it’s flush with the engine block.

Step 11: Install the New Clutch and Flywheel

With the old components removed, it’s time to install the new parts:

1. Position the flywheel: Align and bolt the new flywheel to the engine.
2. Install the clutch disc and pressure plate: Follow the manufacturer’s instructions for proper alignment and torque specifications.

Conclusion

Replacing the clutch in your BMW 328i can be a rewarding DIY project. By following these steps, you'll ensure that your vehicle operates smoothly and efficiently. After completing the clutch replacement, be sure to perform a test drive to confirm everything is functioning properly. If you enjoyed this tutorial, consider watching Part 2 for further guidance on reassembly and additional tips.