'95 525i Clutch Problem

Don Ivey · 02-09-2007, 03:14 PM

Hi, I have a '95 525i with manual trannie, and over the past year or so the clutch has gotten lighter and lighter to depress. Today, after the car sat for a week, I went out and pressed the clutch pedal and it went to the floor. I could pull it up, but it did the same thing again, and I couldn't put the car in gear. I looked under the car, and it looks like a very small amount of fluid of some kind on the pavement about midway under the car where the firewall is. Does this sound like my clutch is gone, or is it possible the slave or master cylinder is leaking/bad? If so, are there any technical articles about repair/replacement of these. Thanks,

Don Ivey
'95 525i

BMWCowboy · 02-15-2007, 06:12 PM

Sounds like ur slave cyl is bad~~>prolly the hose going to it too

Jeron · Jeron's Garage

Would a slave going bad make it easier to depress the clutch? If it wasn't for the clutch getting easier to depress I would have guesses slave or hose leak too.

Don Ivey · 02-17-2007, 05:55 PM

Thanks for all the help, and questions. It turned out to be a slave cylinder gone bad, it was replaced, system bled, and now all is well. The pedal getting lighter could have been my imagination, but I believe it was so. Thanks,

Don Ivey

BMWCowboy · 02-18-2007, 12:54 PM

Wow!!~~> I wz RIGHT AGAIN!!!

roverjosh · 03-13-2007, 03:11 AM

Hello everyone,
I was hoping you folks can help me. I have a 93 520i, eurospec. It has been running great, but I got in the car yesterday and the clutch had no pressure. I can't really get under it verywell because of where it is parked and of course I can't move it without the clutch.
I was wondering where you fill the clutch fluid and how you bleed this system? Do you need to be under the car to do it? If so, I can always guy a jack and some stands.
The reason I am trying to do all this myself is, I live in Italy and it is a little difficult for me to just get a towtruck and call a mechanic, because of the language barrier. So if you folks can offer any assistance, I would greatly appreciate it.

Thanks a million.

Josh Sosbee

Jeron · Jeron's Garage

To bleed the clutch you need to get under and open the bleed nipple while a partner presses the clutch.

In my experience (E36), you need to remove the slave and turn it so that the nipple points up to release trapped air. If you do it by removing the clutch you can push on the slave rod while opening the nipple so you don't need a partner.

This job is a PITA and I would not want to do it in the street. I would find a shop that can tow it for you to save some money and headache. Also, you still need to find out while you have no clutch pressure. Hopefully the slave is bad or a leak.

Clutch slaves are pretty cheap you might want to just buy one and replace it as step one.

roverjosh · 03-13-2007, 02:55 PM

Thank you for the information. I talked to the mechanics at my local hobbyshop on the Navybase. They suggested that I try to do the bleed, because I might have gotten some air in the system through the brake master cylinder. Is is true that the brakes and the cluth are all one hydrolic system?
Again, thanks for the help. I really appreciate it.
Josh Sosbee

Jeron · Jeron's Garage

The clutch and the brakes share the same reserviour so it is one system in some respects.

Are you sayng you let the brake/clutch fluid get low so you think this may have caused the problem? Is there any brake fluid under the car?

Good luck.

roverjosh · 03-16-2007, 01:39 AM

That is the weird thing. I didn't have any problems the day before, when I drove it, and the Brake fluid level is above the Min. level mark, and there is absolutely no pressure on the pedal. I looked under the car and I couldn't find any pools of fluid. The car is parked in a dirt/concrete slab on the edge of a parking area, so it is kinda hard to tell, but if even a small amount had leaked out, I should have seen or at least smelled a puddle under where the slave cylinder is. I am going to bleed the system this weekend with my wife. I will let you know what I find out.

I think you might be right though. My slave cyl. off the tranny is most likely the culprit. I looked at the master off the pedal and it looks clean. All the seals are still there.

Thanks again for your help guys.

Josh

roverjosh · 04-07-2007, 07:16 AM

Ok guys,

Both my Master and slave cylinder were bad. I have reinstalled both the master and slave cylinder. All the nuts are tight I don't see any leaks. That being said I am at a loss for why I can't build up pressure after bleeding the system.
So here is what I have done.
1. installed both master and slave cylinders.
2. opened nipple on slave and pumped the clutch pedal until I saw fluid come out.
3. closed nipple when fluid appeared to be clear and without bubbles.
4. tried to disengage the clutch after closing nipple and the pedal was a soft as it was before. Checked fluid levels. All were good. Tried bleeding again, and not no fluid come out when I press the clutch pedal?

I pushed the pedal to the floor and had my wife hold it down. Then unmounted the slave cylinder and replaced it, all while having the nipple open and then tightening the bleed nipple, once I pushed the slave cylinder all the way back in. This, obviously did nothing.

I am pretty much at a loss here, so any help would be great.
You folks have always been a great help in the past. Thanks in advance.

Jeron · Jeron's Garage

Quote:

Originally posted by Jeron
To bleed the clutch you need to get under and open the bleed nipple while a partner presses the clutch.

In my experience (E36), you need to remove the slave and turn it so that the nipple points up to release trapped air. If you do it by removing the clutch you can push on the slave rod while opening the nipple so you don't need a partner.

Did you try:

1 remove the slave
2 turning the nipple up
3 while a partner is pressing the clutch open the nipple while it points up
(repeat)

You can substitute 3 with; pressing the plunger by hand while opening the nipple

roverjosh · 04-08-2007, 01:54 AM

Ok, so I was partially successful. The clutch has solid pressure, no leaks and everything appears to be working. However, the clutch will not fully disengage. It is as if the slave cylinder doesn't have enough travel to push the clutch plate all the way off.
So, I can start the car in gear and it won't stall, but I can feel the clutch rubbing just enough, not to be able to change gears while the motor is running. The good news is I was able to start stop it enough to get it to a place where I can have it towed.
The remaining question is: Can I buy a longer slave cylinder rod to compensate for the lack of travel? or would I only be adding to my problem?

Thanks for the great help guys, you are life savers.

Jeron · Jeron's Garage

My guess is that your clutch stop is too tall so that you cant depress the clutch fully. Or you got the wrong slave.

roverjosh · 04-09-2007, 12:00 AM

I think you might be right. I checked both parts when I bought them and the master and slave cylinders looked exactly the same, but it still isn't working right. I have a feeling that the master cylinder might actually not have as much travel. I can't really tell.
I am going to take it to a mechanic, because I am out of my skill level at this point.

Thanks for all your help.

Josh Sosbee

Jeron · Jeron's Garage

At least try removing the clutch stop first. It only takes a second to unscrew it from the floor board.

roverjosh · 04-09-2007, 11:41 AM

Jeron, I looked and I couldn't see a clutch stop. There was a metal bracket as part of the spring assembly and a small rubber grommet which I promptly removed, but I didn't see anything. Where would it be? On the floor or higher up on the assembly? Thanks for the great suggestion, by the way.

Josh Sosbee

Jeron · Jeron's Garage

Looks like its #16 here so it may not be adjustible llike it is on the E36.
http://www.realoem.com/bmw/showparts.do?model=HD51&mospid=47375&btnr=35_0055&hg=35&fg=05

roverjosh · 04-25-2007, 12:01 PM

Ok,

Once again, chock it up to inexperience. After pounding the (non-adjustable) pedal stop, Great catch Jeron, that was it, with a hammer a few times, I could get the clutch far enough down to be able to clumsily shift the car. I drove it to my shop on the navy base. Put her on lift checked everything again and then asked the mechanic what he thought. He asked if the new Master cylinder matched the old one perfectly, I said they looked the same. He then asked is the pedal rod the same length? I didn't actually know? So if took the old one and new one off. The old one was 1/2 inch or os longer. That as all the through I needed. Put it all back together and it works like it should.

All I had to do, was seriously scrutinize the new part, before installation, and I might have cought the problem.

Either way, I have learned a lot with this fix.

Thanks a million guys. I couldn't have done it without you.

Jeron, especially you. I couldn't have done this without your help!

Sincerely,

Josh Sosbee

Rixter 1951 · 02-10-2009, 10:07 PM

I just had to say 'thanks' to the forum/Jeron for the answers to this thread. I joined the forum and need help with a similar problem but when I try to open a new thread to ask the question the site keeps asking me to log in..I am logged in so all I can hope for is some mod is around to answer this: I have the same problem with my E34..nearly the same. I removed the slave cylinder to re-build it. I took it apart and there was the spool and seal etc. but also a rubber dust boot (accordion type) INSIDE the slave cylinder ?? Shouldn't it be on the outside of the cylinder pressed over the shaft that actuates the clutch arm.