E86 coupe clutch renewal

S

stan A

Member
Hi , Having owned my car for 3 yrs and never being happy with the clutch engagement, I finally bit the bullet and have just renewed it with a solid flywheel conversion kit from Valeo, kit no 835115. It was a comprehensive kit with new bolts,2 different release bearings included.
There is a very good video on youtube from Bavarian motorsport which I found really helpful [I think it is for an E36 but still relevant to Z4]
In this, the presenter says that a dual mass flywheel should be replaced about 100,000 mls. If it goes,it will wreck your engine- I assume it will bend the crank!. Once out , mine did prove to be knackered, with rotational and wobble play.
One of the worst jobs was getting the exhaust off. The nuts were just about non existent so I cut the bottom 2 studs off with a grinder and had to drill/split off the top 2. The guy said on the video it will take a garage about 4.5 hrs to change the clutch and flywheel. I am now on my third week! but in fairness I have ordered oil seals and parts as I went to make sure I was buying the right thing.
It is now at the 'nearly finished' stage, i am just waiting for an exhaust hanger that I had to cut off- and forgot to order 2 weeks ago.
I have had it running, but it is still on ramps/axle stands so could not try the clutch bight yet, but it does feel good. Previously you had to press the clutch to the floor and the gears were a bit notchy. Forgot to mention my car is on 102,000.
PS, Tried to put this in E86 folder but could not find how to post a topic on there?
 
Sounds like your clutch received quite a bit of abuse from previous owners.

Clutches on these can last 150k miles plus easy.
 
You don't tend to get catastrophic engine failure from a clutch/flywheel wearing - unless you happen to mis-shift at high revs.

I used my Z4MC quite 'vigorously' on road & track and my clutch still lasted 140,000 miles - and the flywheel was still okay, but we replaced it at the same time as we didn't want to have to take it apart again in 20-30,000 miles to do a flywheel.
 
I currently have 195k on my clutch and going strong. Bought the car used last year MOT history all done by BMW shops so felt comfortable with purchase. It is just a fun weekend summer ride as I have 2 other cars to drive for daily use. I plan on a long trip hopefully in a few months to see family which have not seen in 2yrs. Yes it cost $$$ but I had BMW dealer go over the car a complete deep look over checkup. As I wanted to be sure of no potential issues. Car passed no issues including the clutch which I had thought due to mileage would need work. Dealer says clutch still strong no issues!!! So long story guess these clutches do last a long time.
 
Just a quick update- car is now back on wheels and driving again. It has been quite a transformation, it now feels like the clutch is working properly, the gears are smooth to change and it just feels nicer to drive. I do take the point from other owners that mine may have been abused in the past, I hope all of yours go on forever! I do feel that the designers have answered a question that no one asked in producing and fitting dual mass flywheels-I think they are fitted in most modern cars. The solid flywheel conversion seems to work just as well if not better and should now never need replacing, just the clutch plate and cover. Thanks, Stan.
 
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