Clutch help needed

[Gary Waggoner]

So as most of you know I have an S38 in my coupe now. I am having clutch issues and have followed many threads about the 5 speed conversion so I thought I was on top of it. My question is this.... My 265 did not come with a bellhousing so I bought this bell housing off of Ebay shown below. It did not come with the release arm or any other clutch parts so I used the reconditioned 262(?) 4 speed parts(could be wrong geometry?). The new Sachs clutch and throw out bearing kit came complete for an E28 M5 with S38 using a new 1992 M5 S38 fly wheel. I have an E28 Master and E28 Slave, both new and all new hoses, lines etc.. The clutch hydraulics bleed easy from the bottom up but I get only the most minor disengagement like the arm geometry is slightly different, bearing is slightly shorter, etc. I can barely (major effort) move a rear wheel with the clutch pressed and can hear the clutch disc moving on the flywheel. When the clutch is depressed, I can hear the fork/bearing move. Just not enough... ? I am out of my knowledge zone on old/new BMW compatibility stuff so I humbly ask the pros.

 

[sfdon]

Did you measure the slave shaft travel as outlined in the manual?
Did you mic the TO bearing to make sure you didn’t get the short one?
Did you mic the pressure plate bolts?
Did you replace the pivot point?
Any chance this a 1974 bell housing?

 

[Gary Waggoner]

Don, I really appreciate you responding to this. I don't have a manual which maybe the start of my issues. I have done MANY custom clutch conversions and maybe that is the issue here. I assumed the parts I purchased would work together, but something is off. The 74 bell housing is different I assume, but longer by several mm's?

Did you measure the slave shaft travel as outlined in the manual? I did not measure the travel. I have 2 slaves here, one for a later CS and one for a 535i. They are very close to the same and actually react the same installed in this car.
Did you mic the TO bearing to make sure you didn’t get the short one? No I assumed the Sachs kit would be correct. They are about 20mm difference correct?
Did you mic the pressure plate bolts? No, I used new bolts for this PP and disc for a 535i.
Did you replace the pivot point? Yes
Any chance this a 1974 bell housing? I have no idea, very possible. What are the differences?

 

[sfdon]

I’ll send the instructions on measuring shaft travel

 

[wilies13]

I just converted mine from 4 to 5 speed. My E9 is from April 1974 (after facelift)
I reused bellhousing, clutch arm, clutch release bearing and hydraulic cylinder...it just works.
..maybe this helps a little...

 

[Gary Waggoner]

It does help narrow things down some. At least I know what does work . Still trying to figure out where the 74 bellhousing differs from others. Mine is a non motronic 265 bell housing.

 

[Gary Waggoner]

It appears that the 551.9 is the correct bell housing for this conversion as well as the arm that goes with it? 78+ 528i?

 

[Keshav]

It appears that the 551.9 is the correct bell housing for this conversion as well as the arm that goes with it? 78+ 528i?

Should be this one

Bitte entschuldigen Sie die Störung...

 

[Gary Waggoner]

Thanks , but which bell housing? 551.9

 

[Keshav]

1202551.9 is the later style Getrag bell housing used in the 4spd gearbox where the clutch cylinder is outside rather than the older style 1200211.0 where it’s inside.
I pointed out the eBay clutch cylinder that matches the 51.9 type. The older style was in the 72 model cars and newer type in 73, when exactly the change took place I can’t say.
Most prefer the later model due to cheaper clutch cylinder (30 vs almost 200) and convenience in swapping it being outside.
I must admit that mechanics is not my strong point so please confirm from the experts. The cleaner one is the old style...

 

[sfdon]

I’m sorry - swamped today
You must define one key point before you can choose a direction.
Measure the shaft travel of the slave following directions in manual. That’s what the cutout is for.

 

[Gary Waggoner]

1202551.9 is the later style Getrag bell housing used in the 4spd gearbox where the clutch cylinder is outside rather than the older style 1200211.0 where it’s inside.
I pointed out the eBay clutch cylinder that matches the 51.9 type. The older style was in the 72 model cars and newer type in 73, when exactly the change took place I can’t say.
Most prefer the later model due to cheaper clutch cylinder (30 vs almost 200) and convenience in swapping it being outside.
I must admit that mechanics is not my strong point so please confirm from the experts. The cleaner one is the old style...

Thanks, great info

 

[Gary Waggoner]

I’m sorry - swamped today
You must define one key point before you can choose a direction.
Measure the shaft travel of the slave following directions in manual. That’s what the cutout is for.

No problem Don, I will do that tomorrow.

 

[sfdon]

Btw- from memory hahaha - to use an early tranny with the later bell housing and pivot and fork and clip and TO- we would need to change the housing cover. Contact srennoc for more info

 

[Gary Waggoner]

Btw- from memory hahaha - to use an early tranny with the later bell housing and pivot and fork and clip and TO- we would need to change the housing cover. Contact srennoc for more info

What defines early tranny? Not being a smart a$$.

 

[sfdon]

After the changeover in 73

 

[Honolulu]

Once upon a time (and this might totally belong in the Department of Useless Information) I had a '95 325 convertible which gave me clutch trouble. After a lot of humbug, the local pro's determined that the release bearing was binding on the sleeve. One more thing to check - does the release bearing actually travel as it's supposed to. The window in the side of the bell housing may yield an answer, or simply observing the play in the clutch lever as another person presses and releases the pedal.

I sold that dratted 'vert after a couple years for what I had into it. Luckily(?) I got it free, so I broke even and had some cheerful cruising times. The top leaked like a sieve and the "gray" carpets turned out to be actually beige and full of crud.