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BMW Clutch Switch and Pedal Bushing Replacement
 
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Pelican Technical Article:

BMW Clutch Switch and Pedal Bushing Replacement

Nick Czerula

Time:

1.5 hours

Tab:

$50

Talent:

****

Tools:

Phillips & flathead screwdriver, 10mm socket set, diagonal pliers

Applicable Models:

BMW E90 3-Series (2006-11)
BMW E91 3-Series (2006-12)
BMW E92 3-Series (2007-13)
BMW E93 3-Series (2007-13)

Parts Required:

Clutch pedal bushings, clutch switch, MOLYKOTE® D-96 grease, clutch pedal clip

Hot Tip:

When removing clutch pedal from bracket, work gently as to not damage clutch master cylinder

Performance Gain:

Repair faulty clutch pedal bushings

Complementary Modification:

Replace clutch switch and bushing at same time

The clutch pedal bushings work as a friction surface for the clutch pedal and the mounting pin surface. There are two plastic clutch pedal bushings, both the same part number. The bushings wear out over time creating free-play in the clutch pedal and reducing clutch feel and performance. It can feel as if your clutch has slack or poor engagement when the bushings are worn. If you suspect the bushings are worn, grab the clutch pedal and move it side to side. It should lack free-play and lateral movement. If there is excessive movement, replace the clutch pedal bushings. Always grease the new bushing with MOLYKOTE® D-96 anti friction grease or something similar.

The clutch switch is used to notify the DME that you pressed the clutch pedal. The signal generated by the clutch pedal switch is used for engine starting, engine performance and traction / ABS control. The clutch pedal switch is mounted to the side of the clutch master cylinder. Replacing it is quite easy and I will show you how a little later in this tech article.

First, I will describe how to remove the trim panel below the pedal assembly. Then each procedure will be described separately.

Working at the lower trim panel above the pedal cluster, remove three T20 Torx screws.
Figure 1

Working at the lower trim panel above the pedal cluster, remove three T20 Torx screws. (green arrows)

Once you remove the Torx screws, pull the corner of trim panel out of the center console, then pull down and away from the pedal cluster.
Figure 2

Once you remove the Torx screws, pull the corner of trim panel out of the center console, then pull down and away from the pedal cluster.

Lower the trim panel enough to access the electrical connectors (green arrows) Disconnect the speaker and footwell light electrical connectors by pulling them straight out.
Figure 3

Lower the trim panel enough to access the electrical connectors (green arrows) Disconnect the speaker and footwell light electrical connectors by pulling them straight out. Next you will have to disconnect the electrical connectors at the opposite side of the trim panel.

Starting with the fiber optic programming connection, press the release tab and pull the electrical connector off.
Figure 4

Starting with the fiber optic programming connection, press the release tab and pull the electrical connector off. (green arrow)

Then disconnect the antenna connection located a little further back on the trim panel.
Figure 5

Then disconnect the antenna connection located a little further back on the trim panel. To disconnect it, press the release tab while pulling the cable off the module. (green arrow)


Clutch Pedal Bushings
Now that you have removed the trim panel, it's time to start taking the clutch pedal assembly apart.
Figure 6

Now that you have removed the trim panel, it's time to start taking the clutch pedal assembly apart. First you will have to remove the clutch pedal return spring. (green arrow) I like to grab it with a pair of diagonal pliers and disconnect it from the clutch pedal. However, it's a light spring, so you can use your fingers if you prefer.

Working at the clutch pedal assembly, disconnect the clutch pedal return spring using diagonal pliers.
Figure 7

Working at the clutch pedal assembly, disconnect the clutch pedal return spring using diagonal pliers. (green arrow) Grab spring and slide out of hole in clutch pedal.

Next you have to remove the retaining clip from the clutch pedal shaft.
Figure 8

Next you have to remove the retaining clip from the clutch pedal shaft. (green arrow) Using a flatblade screwdriver, release clip in area of yellow arrow and remove from clutch pedal shaft. The yellow arrow shows clip removed and where to lever it open to remove. Once you lever this spot, slide clip off clutch pedal pivot.

Working at the top of clutch master cylinder (green arrow), remove two 10mm fasteners.
Figure 9

Working at the top of clutch master cylinder (green arrow), remove two 10mm fasteners. This photo shows the nuts that are held in place by the bracket. Loosen the bolts from the opposite side of the clutch master cylinder. Once you get the bolts about half way out, you will have to hold the nuts with an open end wrench.

Next, remove clutch pedal from vehicle by sliding off shaft.
Figure 10

Next, remove clutch pedal from vehicle by sliding off shaft. Be gentle and careful not to damage connections at clutch master cylinder. The clutch pedal will stay up near the pedal cluster during bushing replacement. Remove clutch pedal bushings from clutch pedal and replace with new.

Slide the new inner bushing (green arrow) on first, then apply a small amount of MOLYKOTE® D-96 anti friction grease or similar to bushing.
Figure 11

Slide the new inner bushing (green arrow) on first, then apply a small amount of MOLYKOTE® D-96 anti friction grease or similar to bushing. Then slide the clutch pedal back onto shaft. Apply a small amount of MOLYKOTE® D-96 anti friction grease or similar to the outer bushing. Then slide outer bushing into pedal pivot once pedal is on shaft.

Be sure clip is properly installed as shown in picture.
Figure 12

Be sure clip is properly installed as shown in picture. (green arrow) Install and tighten clutch master cylinder fasteners. Install clutch pedal spring and check clutch pedal operation.

Clutch Pedal Switch
Now that you have removed the trim panel, you will have to disconnect the clutch switch electrical connector.
Figure 13

Now that you have removed the trim panel, you will have to disconnect the clutch switch electrical connector. It is located on the fender side of the clutch switch. Grab the electrical connector (green arrow) and pull it straight out of the clutch switch.

To remove the clutch switch from the clutch master cylinder, grab the top of switch near where electrical connection is, and pull away from clutch master cylinder.
Figure 14

To remove the clutch switch from the clutch master cylinder, grab the top of switch near where electrical connection is, and pull away from clutch master cylinder. This will unclip the switch and release it from the clutch master cylinder. To install the new switch, slide the rear of switch into clutch master cylinder, then press area near electrical connection into the clutch master cylinder. The switch will snap into place. Once installed, connect electrical connector and reassemble trim panel. Check that the clutch switch is functioning properly by starting your vehicle and you are done.

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Comments and Suggestions:
Levanime Comments: Could you specify the part number of the connector that is getting getting in the clutch switch ? been searching for it for a while
February 10, 2015
  Followup from the Pelican Staff: Connectors can be the hardest part to look up, due to BMW clumping them into one place. Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need.
- Nick at Pelican Parts
 

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Page last updated: Sat 12/3/2016 02:22:16 AM