[flacoramos]

In before @platii

• The error seems to be that the zero point of the clutch position is out of range. Would this be caused by a lower general thickness of the friction material (which is what I observed with the Kevlar clutch material, as compared with the standard/remaining organic clutch material)

Very likely. Note clamping force will be decreased with thinner material.

Can I somehow trick the software into thinking that the clutch engagement point is in range, somehow?

Not the software. But guess you could try adding shims between slave and trans and/or between PLCD and slave. Not sure whether it'll work or if it's worth the effort tho... Up to you to decide.

Is it possible this is a result of my "fix" of the sensor strip wires?

Unlikely.

 

[flacoramos]

Yes the total plate thickness, about 2.5mm on each friction side.

Was this kevlar clutch used since a year ago?.

Curious where did you get those numbers? I saw newtis only gives a measurement limit to rivets, so not very useful.

As an FYI newtis shows BMW uses a clutch wear-measurement tool on other cars, not for SMGs tho.

I still have my old smg clutch but with recent snow not in the mood to pull it out.

 

[flacoramos]

OK, quick update. I ended up removing the transmission (Again. If I'm not careful, I might get good at this) and discovered the my rebuild of the slave cylinder had failed. The internal lock ring that holds the boot down had come out, which may have been playing a role in some of the errors.

At any rate, I have now ordered a new, standard clutch disk, as well as a new E46 slave cylinder (I can't help myself from experimenting!), and I'll update this thread once I get everything installed. With the bolts swapped from the E60 slave cylinder, if the SMG2 slave cylinder works, it's half the price or less than the E60 version. Which is somewhat suspect in and of itself, admittedly.

Cheers

Someone posted on insta about the E46 SMG slave. Yes it fits, just need to machine flat the surface that the PLCD attaches to. I remember sharing the link.