I have a 99' 540i/6 with sport package at 115k miles and I am completely out of my league when talking about the following.

Ok, my driveshaft is making a clanging noise. Take it to the shop and they say it needs replacement. I tell them that while they have the driveshaft out, please go ahead and take the transmission out and check the clutch. It had been making noise when engaging it. Now my clutch is new, about 10k on it. They do so, and call me and say basically, "What the H**L happened to your flywheel it is burned?"

I told them that when I had my clutch replaced a little less than a year ago the mechanic who replaced told me "I have good news for you, I replaced your clutch with no problems and I measured your flywheel and it was perfect, no replacement or machining required." I know nothing of these things, so I am happy that I have saved money. My new mechanic says that is the stupidest thing he has ever heard, you always machine or replace the flywheel when you are replacing the clutch.

So now in addition to replacing the driveshaft, I am replacing the clutch and flywheel. Ouch. Does this sound right?

Thanks in advance.

Hmm - I had some mild scorching on my flywheel but it was fine for re-use at 93k miles - no issues since in almost 5k miles of driving. Your new mechanic doesn't sound like he knows what he's doing... What kind of noise did you hear when engaging the flywheel? Did he say that the flywheel was the source of the noise?

..My new mechanic says that is the stupidest thing he has ever heard, you always machine or replace the flywheel when you are replacing the clutch...

AFAIK, you shouldn't re-surface dual-mass flywheels. Here's a link to a LUK document about that. (http://www.schaeffler.com/remotemedien/media/_shared_media/library/downloads/LuK_Schadensdiagnose_PKW_en.pdf) Maybe you new mechanic doesn't have much experience with BMW clutches.

Why didn't you take the car back to the first mechanic?

Thank you for the replies. I read the document and it seems clear to me that resurfacing is out of the question. I am assuming that the 540i/6 uses a Dual Mass flywheel? If so, does that mean I SHOULD have it replaced with every clutch replacement? Is that the norm?

Thanks again.

Supark, thanks for your reply. I am going to go down there on Monday and see it for myself!