oil BMW 540i 2000 E39 Workshop Manual

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330-39
I Rear suspension1
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Models with coil springs: Fit spring correctly in lower spring
seat.
* Models with air suspension: Fit eccentric lug at bottom of
air spring in recess of wheel carrier spring seat.
Always use new self-locking nuts.
- Make sure all threaded bolts, nuts and mating surfaces are
clean.
a Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
Stake axle collar nut afler tightening.
Tightening torques
ABS pulse sensor to wheel bearing 8 Nm (6
ft-lb)
carrier
Air spring to wheel bearing carrier 20 Nm (15 ft-lb)
Brake rotor to hub 16 Nm (12
it-lb)
Rear axle shaft to hub (M27) 300 Nm (221 ft-lb)
Rear brake pad carrier (caliper) to wheel 65 Nm (48 ft-lb)
bearing carrier
Road wheel to hub
120ilONm
(89 k7 ft-lb)
Swing arm to wheel bearing carrier 256 Nm (189 it-lb)
Upperfrontcontrol arm (traction strut) to 65 Nm (48 ft-lb)
wheel carrier
Upper rear control arm to wheel carrier 142 Nm (105 ft-lb)
Rear wheel bearing, replacing
< The rear wheel bearing is integrated with its mounting flange.
1. Torx bolt
2. Wheel bearing and mounting flange
3. Wheel hub
4. Collar nut
- Raise rear end of car and remove wheel.
WARNING -
Make sure the car is firmly supported on jaclc stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension parts.

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--. ..
Rear Suspension
4 Remove wheel bearing assembly.
4 Remove inner wheel bearing race with BMW special tools 33
1 312
and 00 7 500 or equivalent.
- Install new wheel bearing assembly. Malte sure mounting
surfaces are free of dirt and grease.
Tightening torques
Wheel bearing to wheel bearing carrier (use new
Tom bolts)
Stage
1 30 Nm (22 ft-lb)
Stage 2 90" torque angle
4 Reinstall wheel hub.
Lightly oil wheel bearing and axle shaft contact surfaces on
wheel hub.
Use BMW special tools
33 2 115,33 2 116 and 33 2 118
or equivalent press tools to press wheel hub to bearing.
CAUTION-
BMWspecifies speclaltools to pull the wheel hub through the
wheel bearing into position. If using alternative tools, be sure
to support the bearing inner race when pressing orpulling the
hub into place.
- Lightly oil the bearing surface of the axle collar nut and install.
Tighten collar nut firmly, but do not fully tighten it at this time.
WARNING-
For safety reasons, the axle collar nut should only be tight-
ened to its final torque with the wheel installed and the car
lowered to the ground. However, loading the bearing without
the nut tightened sufficiently may damage
the bearing.

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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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Final Drive
Tightening torques
F~nal drive to rear axle carrier 105 Nm (77 it-lb)
Driveshaft CV joint to final drive flange
- MlO (Torx bolt) 70
Nm (51 ft-lb)
- M8 (compression nut) 32 Nm (24
ft-lb)
Drive axle to final drive
ilange
Torx bolts (M10) 83 Nm (61 ft-lb)
Torx bolt with
rlbbed teeth (M10) 64 Nm (47 ft-lb)
Torx bolt
wlth ribbed teeth (MI0 sliver) 80 Nm (59 ft-lb)
Torx
bolt with ribbed teeth (M10 black) 100 Nm (74 ft-lb)
* Torx bolt with ribbed teeth (M12) 135 Nm (100 ft-lb)
Differential oil level, checking
The E39 differential is filled with lifetime oil that ordinarily
does not need to be changed. BMW recommends using only
a specially formulated synthetic gear oil
(SAF-XO) that is
available through an authorized BMW dealer parts depart-
ment. For additional information on this lubricant and any oth-
er lubricants that may be compatible, contact an authorized
BMW dealer service department.
< Check rear differential oil level at filler plug (arrow).
- Check lubricant level with car on a level surface:
Level is correct when fluid just reaches edge of filler hole.
If necessary, top up fluid.
* Replace filler plug sealing ring.
Install and tighten oil filler plug when oil level is correct.
NOTE-
Use either a 14 mm or 17 mm Allen socket to remove the
drain plug.
If car is raised in the air. it should be level when
checkino " or filling final drive fluid level.
- Tightening torque -
Filler plug to final drive housing 70 Nm (52
ft-lb) -

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331-9
Final Drive
Coat drive flange sealing area and seal lip with differential oil.
* Install drive flange on pinion shaft.
Using
BMW special tools 23 1 300,33 1 341 and 23 1 302
press drive flange on to pinion shaft only to extent as to al-
low collar nut to be installed.
4 Tighten collar nut only until previously marked points are
aligned (arrow).
CAUTION-
Do not underany circumstances tighten collarnut beyond the
markedpoints,
othe~lise clamping sleeve will have to be re-
placed.
- Using a suitable drift, install new collar nut locking plate
Stalte plate in place.
- Remainder of installation is reverse of removal.
- Check and, if necessary, set differential oil level. See Differ-
ential oil level, checking.
Tightening torque Driveshaft
CV joint to final drive flange
MI0 (Torx bolt) 70 Nrn (51 ft-lb)
ME (compression nut) 32 Nrn (24 ft-lb)

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331-1 1
Final rive(
< Coat seal with differential oil and drive into place using BMW
special tools 00 5 500 and 33 4 250 or equivalent.
Replace snap ring (arrow) on final drive output flange shaft.
Coat output flange
shaft with differential oil where it con-
tacts shaft seal.
. Push output flange into final drive until flange splines en-
gage splines of differential gear and snap ring can be
heard to snap into place.
- Remainder of installation is reverse of removal.
Check and, if necessary, set differential oil level. See Dif-
ferential oil level, checking.
Tightening torques Drive axle to final drive flange
Torx bolts
(M10) 83 Nm (61 ft-lb)
Torx bolt with ribbed teeth (M10) 64 Nm (47 it-lb)
Torx bolt with ribbed teeth (Mi0 silver) 80 Nm (59 ft-lb)
Torx bolt with ribbed teeth (MI0 black) 100 Nm (74 ft-lb)
- Torx bolt with ribbed teeth (M12) 135 Nm (100 ft-lb)

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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 ~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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331-16
I Final Drive
Worlting at top of coil spring, press center cap down or pry
upward to remove. If pushed down, remove from inside coil
spring.
4 Worlting from underneath, position BMW special tool 33 2
301
between 2nd and 3rd spring coil from the bottom.
Make sure tool recess faces upward.
Worlting in cargo compartment, guide BMW special tool
33
2 304
from above and thread into special tool 33 2 301.
4 Worlting in cargo compartment, attach BMW special tools 33
2 302.33
2 303 and 33 2 305 to special tool 33 2 304.
- Use special tool 33 2 306 to compress spring.
Tighten until lower spring end lifts off spring seat on wheel
bearing carrier.
- Model with air springs: Loosen compressed air pipes at air
distribution assembly to release system pressure.
WARNING-
The vehicle will lower when tlie airpipes are loosened.
- Remove final drive. See Final drive, removing and install-
ing.