installing AC BMW 528i 2000 E39 Workshop Manual

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33UFinal Drive
General ........................... ,331 -2 Drive Axles ....................... 331 -1 4
Special tools
........................ ,331 -2 Drive axle assembly ................. 331-14
Aluminum suspension components
...... ,331-4 Drive axle, removing and
installing (sedan)
.................... 331-14 ........................ Final Drive ,331 -5
Drive axle, removing
........... ...... Final drive, removing and installing ,331-5 and (Sport Wagon) 331-15
...................... Differential oil level, checking ........... ,331-6 CV joint boots 331-17 Final drive in~ut shaft seal, replacing ..... ,331-7 .
Final drive oitput shaft seals, replacing . . ,331-10
Final drive cover, removing and installing ,331-12
Final drive mounts, replacing .......... ,331-12

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Final Drive
Final drive, removing and installing
- Raise rear of car.
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for the purpose. Place the jaclc stands beneath struc-
tural chassis
~oints. Do not i lace iaclc stands under
( suspension barfs.
Remove exhaust system. See 180 Exhaust System.
Disconnect drive shaft from final drive. See
260 Driveshaft.
Remove drive axle CV joint bolts (arrows) at left and right
sides. Suspend drive axles from body using stiff wire.
4 Support final drive with BMW special tool 33 4 390.
* Remove front final drive mounting bolt.
Remove rear final drive mounting bolts
(2).
Carefully lower final drive unit.
- To install, use BMW special tool 33 4 390 to lift final drive into
place.
CA UTIOP&
The following sequence must be used when installing the fi-
nal drive to prevent torsion stress on the final drive during in-
Install mounting bolts and finger tighten only.
Remove final drive support.
Tighten both rear mounting bolts.
Tighten front mounting bolt.
NOTE-
Use new self-locking nuts.
- Check differential oil level. See Differential oil level, check-
ing.
- Remainder of installation is reverse of removal.

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331-12
Final Drive Final drive cover, removing and installing
- Remove final drive. See Final drive, removing and install-
ing.
I 1 4 Remove fasteners (arrows) from rear cover and remove cov-
er.
Clean cover and final drive housing sealing surfaces.
Install new
gasket with cover.
* Installation is reverse of removal.
- Check differential oil level. See Differential oil level, check-
ing.
Tightening
torque
Final drive cover to final drive housing
. M10 (8.8 grade) 45 Nm (33 ft-lb)
M10 (10.9 grade) 90 Nm (66 ft-lb)
Final drive mounts, replacing
- Remove final drive. See Final drive, removing and install-
ing.
Rear final drive mounts
- Remove rear final drive rubber mounts using BMW special
tools333314,333315,334 181, and334 183.
4 Coat new mount with CircolightB anti-friction agent and in-
.
stall, noting the following:
Long bushing on mount must face forward (arrow).
A shows installation position of mounts.

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Final Drive
Drive axles use constant-velocity (CV) joints on both ends.
For replacement parts, only CV joint boots or complete axles
are offered by BMW. The procedure for drive axle removal
varies for sedan and sport wagon. Follow the appropriate pro-
cedure below.
Drive axle assembly
1. lnner CV joint
2. Drive axle
3. Outer CV joint
4. Collar nut
5. Outer CV boot kit
6. lnner CV boot kit
7. Circlip
8. Dust cover
9. Reinforcement
10. Torx bolt
Drive axle, removing and installing (sedan)
4 With an assistant applying brakes, break free staked collar
nut (arrow) at center of rear wheel hub. Do not remove com-
pletely.
NOTE-
The drive flange collar nut is tightened to a torque of over 300
Nm (221 ft-lb). Male sure the car is firmly on the ground.
- Raise rear of car. Remove rear wheel
WARNING -
Make sure that the car is firmly supported on jack stands de-
signed for the purpose. Place the
jack stands beneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Remove f~nal drrve. See Final drive, removing and install-
ing.

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Final ~rivel
4 Remove staked collar nut and press output shafl out of wheel
hub with special
BMW tool 33 2 111/116/117.
- Remove drive axle.
- Installation is reverse of removal, noting the following:
Use a new collar nut.
a Apply a light coating of oil to contact face of collar nut and
install it loosely.
* Install road wheel and lower car to ground.
- With an assistant applying brakes, tighten drive axle collar
nut to its final torque.
Stake collar nut.
Tightening torques
-
Drive axle collar nut to drive flange M27 300 Nrn (221 ft-lb)
Drive axle to differential flange
* M10x20 rnm black Torx bolt
83 Nrn (61 ft-lb)
M10x20 rnrn silver Torx bolt
100 Nrn (74 ft-lb)
Road wheel to hub 120 Nrn f 10 (89 ft-lbf7)
Drive axle, removing and installing
(Sport Wagon)
4 With an assistant applying brakes, brealc free staked collar
nut (arrow) at center of rear wheel hub. Do not remove com-
pletely.
NOJE-
The drive flange collar nut is tightened to a torque of over 300
Nm (221 ft-lb). Make sure the car is firmly on the ground.
WARNING -
Disable airsupply pump (if applicable) by disconnecting elec-
tricalplug before performing any repairs. Pump is located be-
neath a cover under the spare tire
in the floor of the cargo
compartment.
- Raise rear of car. Remove rear wheel.
WARNING -
Malce sure that the car is firmly supported on jack stands de-
signed for the purpose. Place the jack stands beneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Models with rear coil springs: Remove cargo compartment
floor carpet.

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331-17
Final ~rivel
4 Remove staked collar nut and press output shaft out of wheel
hub with special
BMW tool 33 2 11 111 161117.
- Remove drive axle
- Installation is reverse of removal, noting the following:
* Use a new collar nut.
- Apply a light coating of oil to contact face of collar nut and
install it loosely.
Install road wheel and lower car to ground.
* With an assistant applying brakes, tighten drive axle collar
nut to its final torque.
Stake collar nut.
Tightening
torques
Drive axle collar nut to drive flange M24
300 Nrn (221 ft-lb)
Drive axle collar nut to drive flange M27
300 Nrn (221 ft-lb)
Drive axle to differential flange
M10x20 rnrn blaclc Torx bolt 83 Nrn (61 it-lb)
- M10x20 rnrn silver Torx bolt loo Nrn (74 ft-lb)
Road wheel to hub
120 Nrn+lO (89tt-lbi-7)
CV joint boots
NOTE-
When replacing a CVjoint boot, use a complete CVjoint
boot repair kit. The lit will include a new boot, clamping
bands, special lubricant, and a new inner CV joint circlip.
The lit is available from an authorized
BMW dealerparts
department.
The outer CVjoint cannot be removed from the axle
shaft
In order to replace the outer CV boot, it is necessary to re-
move the inner joint and boot first.
If the
CVjoints are worn or defective, a complete rebuilt
axle shaft is available from an authorized
BMW dealer
parts department.
- Remove appropriate axle shaft. See Drive axle, removing
and installing (sedan), or Drive axle, removing and in-
stalling (Sport Wagon).
- Working with axle shaft at bench, cut off old boot clamps and
remove boot. Clean old grease off joint and shaft. Use new
grease from CV joint boot kit.
4 Remove dust cover from CV joint and remove circlip (arrow)
retaining joint inner hub to axle shaft.

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I Final Drive
4 Support inner hub with BMW special tools 26 1 110 and
press axle shaft out of joint using BMW special tool 21 2 120.
- Clean all old lubricant off shaft splines and inner joint splines.
If the CVjoint must be disassembled for cleaning and inspec-
tion, be sure to matchmark inner and outer race and interme-
diate ball cage. This allows reassembly
ofparfs in their
original positions.
NOTE-
To inspect a CVjoint, clean away the grease and loolc forgall-
ing, pitting, and other signs of wear orphysical damage. Pol-
ishedsurfaces or visible ball traclts alone are not necessarily
cause forreplacement. Discoloration due to overheating indi-
cates
laclt of lubrication.
- Slide CV joint boot onto axle shaft
- Apply LoctiteO270 or an equivalent heavy-duty loclting corn-
pound to drive axle splines. Position new CV joint on shaft so
that raised or taller side of hub is facing shaft.
WARNING-
Do not let the locking compound contact the balls in the joint.
Apply only a thin coat to cover the splines.
While supporting axle shaft with BMW special tool
33 2 130
press inner hub of CV joint onto shaft. Install a new circlip.
- Install new boot clamps.
- Use sealing gel to seal dust cover to CV joint prior to reinstal-
lation.
NOTE-
* Do not let the ball hub pivot too far in the outer ring of the
joint.
Tlie balls will fa1 out.
Before installing each small boot clamp be sure to
'burp"the
boot by flexing the CVjoint. A small screwdriver inserted be-
tween the boot and the axle shafl will help the process.
CV joint lubricant capacity
Wheel hub end
80 gram (2.8 oz)
Differential end
85 gram (3.0 oz)

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General ........................... .34 0.2
Special Tools
....................... .34 0.2
E39 brake system
.................... .34 0.4
Electronic braking and stability control
.... .34 0.4
Troubleshooting
..................... .34 0.5
Warnings and cautions
................ .34 0.7
Bleeding Brakes ................... .34 0.8
Brakes, bleeding
..................... .34 0.9
Brake Pads, Calipers and Rotors ... .34 0.1 1
Braking system components .......... .34 0.11
Brake pads,
checking and replacing ..... .34 0.12
Brake rotors, removing and installing
.... .34 0.15
Master Cylinder .................. .34 0.16
Master cylinder, removing and installing
. .34 0.17
Brake Booster .................... .349 0.1
Brake booster check valve
............ .34 0.19
Brake booster, removing and installing
.. .34 0.20
Parking Brake .................... .34 0.22
Parking brake components
............ .34 0.22
Parking
brake, adjusting .............. .34 0.22
Parking bralte shoes, removing
and installing
....................... .34 0.23
Parking
brake cable, replacing ......... .34 0.24
ABS Component Replacement ..... 340-26
Wheel speed sensor. replacing
......... 340-26
ABS impulse wheel
.................. 340-27
DSC lateral acceleration or
rotational rate (yaw) sensor. replacing
... 340-27
DSC steering angle sensor.
removing and installing
............... 340-28
DSC precharge pump.
removing and installing (1998 models)
... 340-29
DSC pressure sensor
(1 999 - 2002 models) ................ 340-30
ABS /traction electronic control
module
(1 997 -1 998 models) .......... 340-31
ABS
/ DSC control module
(1 999
- 2002 models) ................ 340-31
ABS
/ traction control hydraulic unit.
removing and installing
............... 340-31

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340-1 4
Brakes
4 Apply a thin coating of BMW anti-squeal compound to caliper
contact face
(arrow).
Do not apply grease to brake pad backing plate.
Right Left
CAUTION-
Do not let calliper rubber dust sleeve come in contact with
anti-squeal compound. The rubber will swell and deteriorate.
4 Apply a thin coating of BMW anti-squeal compound to bralte
pad rests (arrows) on pad carrier.
4 When installing directional brake pads, install the marked
pads as shown.
NOTE-
BMW-supplied (OEM) front brake pads may be marked as di-
rectionalpads. Aftermarket brands are generally not labeled
as directional. When installing directional pads, be sure to in-
stall them as indicated in the illustration.
- Where applicable, insert brake pad wear sensor into cutout
in new pad. Push sensor into pad cutout until it locks into
place.
- -
- NOTE-
If brake lining indicator light illuminatedprior to brake pad re-
placement, replace wear sensor.
- Route pad wear sensor wiring through caliper opening and
under bleeder dust cap.

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340-1 5
Brakes
- Remainder of installation is reverse of removal.
- Clean brake caliper mounting bolts (7 mm Allen). Replace
ones which are not in perfect condition. Do not grease.
Top up brake fluid to MAX marking.
- Before driving car, pump bralte pedal several times so that
brake pads contact brake rotors.
Check that brake fluid level is correct. Top up if necessary.
Hold ignition key for at least
30 seconds in accessory po-
sition without starting engine. This clears any fault codes in
memory and turns off brake pad warning light.
Tightening torques Brake caliper to pad carrier
(7 mm Allen)
Front caliper
30 Nm (22 It-lb)
- Rear caliper 28 Nm (21 It-lb)
Road wheel to hub
120i 10 Nm (89i7 ft-lb)
Brake rotors, removing and installing
- Raise car and remove wheels
WARNING-
Male sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
Remove brake caliper carrier bolts (arrows). Suspend brake
caliper from chassis using stiff wire.
NOTE-
Hydraulic brake line remains connected.
4 Remove bralte rotor mounting screw (arrow) and remove ro-
tor.
- Inspect rotor for cracks, signs of overheating and scoring.
- Minimum allowable thickness (MIN TH) is stamped on rotor
hub. Measure rotor braking surface with a micrometer at
eight to ten different points and use the smallest measure-
ment. Compare to specifications in table below.
- If rotor does not pass minimum thickness requirements or is
damaged, replace rotor.