Where's this plug go? :) Clutch job almost done...
 

So I'm 90% done with the clutch/flywheel/rear main job on my '03 S, and everything went really well, got the whole thing done over 2 days a week apart, about 14-15 hours of labor at a moderate pace. No air tools, no lift, one crappy jack - two guys on the disassembly last week (me and my friend) three of us this week - though it counted for about 2.5 ;) Couple trips to Autozone and BK too!

Aside from getting the transmission input shaft to slide into the clutch disc (which was by far the hardest part of the job) there are only two questions I've got left.

1. The small half-arc piece of metal held in by two 10mm bolts just above one of the halfshaft inputs to the trans - it kept us from installing the trans because it hit the flywheel. I took it off. Saw nothing it could be doing - I'm sure it's there for a reason, but it wasn't going on with it. What is this piece, what does it do, and do I really need it?

2. Also, I'm really good at placing plugs/harnesses where they go, remembering which plug goes where, etc, but there's one plug I can't find the home for. I removed the A/C condenser and lines (damaged condenser, compressor inop) and taped off the (high?) pressure line plug, but off the same harness is one other plug. No idea where it goes. Any ideas???

Thanks!!

PS - Not a bad job - take your time, read k-huevo's directions over, and over, and over again :), be prepared to get messy, and anyone considering themselves a 6 out of 10 mechanically could do this no sweat. TRY IT! There's enough info and members on here to get you out of any jam!

According to this pdf Attachment 44585 the arc plate isn't a critical component.Did you try looking at the here at the diagrams as to where the plug goes?

AMAZING - thanks so much for that PDF! Wish I had that last week taking everything apart lol - no offense k-huevo!

Didn't think to remove the trans mount - that would have given us clearance against the framerails. Also, we removed the transmission bolts on top without removing the wiring bracket in front of them - talk about doing things the hard way :)

http://www.realoem.com/bmw/showparts...19&hg=64&fg=60

The wiring connector I know about is #22, which plugged into #5. The plug in question is on that same harness....where the heck did it plug in? Fan maybe? That's not installed again yet, maybe that's all I'm missing.

"1. The small half-arc piece of metal held in by two 10mm bolts just above one of the halfshaft inputs to the trans - it kept us from installing the trans because it hit the flywheel. I took it off. Saw nothing it could be doing - I'm sure it's there for a reason, but it wasn't going on with it. What is this piece, what does it do, and do I really need it?"

It's just a tiny cover plate to not let crap into flywheel housing. It was supposed to come off as you removed the trans to aid the eventual installation, as you found out the hard way. Just pop it back on now if you have not installed your passenger drive shaft and starter motor.

Good to hear you're almost done! :thumbsup:

Jeremy

Any ideas on that plug?

The connectors bundled with your reverse switch connector are your power steering pump and fan connectors. You also probably removed the water temp sensor (on the side of the head) and your throttle body. My guess is that you are putting stuff back together, haven't replaced your TB, and are looking at the connector, wondering where it connects to. Am I right?

Reverse switch connector=gear selector sensor on the top of the tranny towards the back near the shift linkage? If not maybe I missed that one...

PSP/fan connectors all back in place. Water temp sensor (ds of head, plugged straight into side w/red safety lock on connector) is connected, as is the sensor directly above it, and the throttle body connection is plugged in too. Essentially, car is back together, ready to go aside from the radiator, but there's the one smaller plug that was connected to the A/C pressure line, I removed that and taped it off as I removed the lines, but there's another plug splitting off the same harness - that's the one in question.

Basically, I got everything together, the only remaining plug was the above mentioned one, I just tucked it under the airbox where the A/C plug routes from, and put the airbox back in.

AC clutch connector on compressor? Beats me. You'll find it when you do the final assembly!

Jeremy

I guess I'm not clarifying - the car is together, all plugs routed and secured, all parts installed, aside from the radiator. So unfortunately the assembly isn't helping! :)