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Clutch Switch Testing and Replacement
 
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Pelican Technical Article:

Clutch Switch Testing and Replacement

Nick Czerula

Time:

1.5 hours

Tab:

$50

Talent:

****

Tools:

Phillips & flathead screwdriver, DVOM

Applicable Models:

BMW 525i/xi Sedan (2004-07)
BMW 528i/xi Sedan (2008-10)
BMW 530i/xi Sedan (2004-07)
BMW 530xi Wagon (2006-07)
BMW 535i/xi Sedan (2008-10)
BMW 535xi Wagon (2008)
BMW 545i Sedan (2004-05)
BMW 550i Sedan (2006-10)

Parts Required:

Clutch pedal switch

Hot Tip:

Use a high impedance DVOM

Performance Gain:

Repair faulty clutch switch

Complementary Modification:

Replace brake light switch

BMW E60 models are equipped with an electronic clutch switch, mounted to the clutch master cylinder. This switch is a magnetic actuated switch, sending an open or closed signal to the DME depending on clutch pedal position. When the clutch is pressed the switch closes. When the clutch switch is not pressed, the switch is open. 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. It clips onto the side of the clutch master cylinder, secured via a plastic tab on the switch. Replacing it is quite easy. Also, I will show you a little later in this tech article how to test it for faults.

Remember that your car may have been serviced before and had parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Remove the lower dashboard trim near the pedal assembly. See our tech article on lower dashboard trim removing.

Now that you have removed the trim panel, you will have to disconnect the clutch switch electrical connector.
Figure 1

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 (red arrow) and pull it straight out of the clutch switch.

To remove the clutch switch from the clutch master cylinder, grab the top of the switch near where the electrical connection is and pull it away from the clutch master cylinder.
Figure 2

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

The switch has four wires going to it: a ground (green arrow), two eight-volt feeds (red arrows) and the signal wire (yellow arrow).
Figure 3

The switch has four wires going to it: a ground (green arrow), two eight-volt feeds (red arrows) and the signal wire (yellow arrow). To test, you need to confirm the ground and eight-volt feeds are present and that the signal occurs when the clutch pedal is pressed. Confirm the wiring for your vehicle with a current wiring diagram. All testing has to be done with the key in the ON position.

Connect your DVOM to the signal wire (red arrow).
Figure 4

Connect your DVOM to the signal wire (red arrow). With the clutch pedal up (yellow arrow), it should read about 0.0 volts.

Connect your DVOM to the signal wire (red arrow).
Figure 5

Connect your DVOM to the signal wire (red arrow). With the clutch pedal pressed (yellow arrow), it should read about 8.0 volts.

Remove the clutch switch from the clutch master cylinder.
Figure 6

Remove the clutch switch from the clutch master cylinder. Then reconnect the electrical connector. Connect your DVOM to the signal wire. Then with a magnet, touch the switch. It should switch from zero volts, when the magnet is not touching the switch (red arrow), to about 8.0 volts, when the magnet is touching the switch (green arrow).




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Comments and Suggestions:
SPAMHEAD Comments: VERY GOOD DESCRIPTION A WIREING DIAGRAM OF THE CIRCUIT WOULD HELP AS WE ARE TRYING TO FIT A MANUAL DDE & CAS UNIT & KEY USED PARTS TO AN AUTOMATIC & NEED TO TELL THE CAS UNIT THE CLUTCH PEDAL IS DOWN TO TURN THE CAR OVER IE WHAT PINS THE CLUTCH PEDAL WIREING COME FROM THANKS DAVID C
June 16, 2016
  Followup from the Pelican Staff: Wiring can vary depending on model, best bet is to get the manual. - Nick at Pelican Parts  

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Page last updated: Sat 12/3/2016 02:42:37 AM