1997 BMW 540i DRIVESHAFT

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330-28
Rear Suspension
4 To install, jack subframe into position. Install and tighten sub-
frame mounting bolts. Note that on each bolt, rubber-coat-
ed detent plate
(arrow) must be installed at rear in driving
direction.
Tightening torques
Rear
subframe to body (M12) 163 Nm (120 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Make sure long lower strut bushing fits in hole in wheel
bearing carrier.
111 0 Tighten suspension arm and shoclc absorber fasteners to
502330036 final torque only afler vehicle has been lowered and sus-
pension has settled.
Have car professionally aligned when job is complete
Tightening torques
ABS pulse sensor to wheel bearing carrier 8 Nrn (6 ft-lb)
Brake rotor to hub
16 Nm (12 ft-lb)
Driveshaft
CV joint to final drive flange
- MI0 (Tow bolts) 70 Nm (51 ft-lb)
MB (compression nut) 32
Nm (24 ft-lb)
Rear brake pad
carrler (caliper) to wheel 65 Nm (48 ft-lb)
bear~ng carrler
Rear strut to
wheel bearlng carrler 127 Nm (94 ft-lb)
Road wheel to hub
120210Nrn
(89 57 ft-lb)
Rear axle assembly, removing and
installing (Sport Wagon models)
Incaseof damage to thesubframe, or if apressed-in bushing is
worn, remove
subframe by removing complete axle assembly.
In Sport Wagon models with conventional coil spring, lower
subframe slowly, making sure rear springs stay on spring
seats.
In models with air suspension
(EHC), disable the air supply
pump, deflate the air springs and disconnect them from the
wheel carriers before lowering the subframe.
- Raise car and remove rear wheels.
WARNING-

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Rear Suspension
- Remove exhaust system. See 180 Exhaust System.
- Detach driveshaft from differential. See 260 Driveshaft.
- Remove brake caliper and brake disc. Hang brake caliper
aside with stiff wire. Do not disconnect brake fluid hose. See
340 Brakes.
- Remove left and right ABS sensors from wheel bearing car-
riers.
Disconnect parking brake cable from brake shoe expander.
See 340 Brakes.
Remove heat shield from above driveshaft
If equipped, remove ride height sensor connectors
CAUTION-
Models with air springs: Disable air supply pump by discon-
necting electrical plug before performing any repairs. Pump is
locatedbeneath a coverunder
thespare tire in the floorof the
carqo compartment.
Models with air springs: Loosen compressed air pipes (ar-
rows) at air distribution assembly to release system pres-
sure.
WARNING -
Vehicle will lower when the air pipes are opened. 1
- Working underneath rear suspension, lift wheel bearing car-
rier to relieve rear spring tension. Then unbolt air spring
mounting bolt from seat on wheel bearing carrier.
4 Support final drive unit from below using transmission jack
(BMW special tools 00 2 030 and 33 4 390 or equivalent).
NOTE-
Special tool 33 4 390 will need modifications to cradle the fi-
nal drive properly
4 Remove right and left suspension trim panels (arrow),

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Rear Suspension
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Tighten suspension arm and shock absorber fasteners to
final torque only afler vehicle has been lowered and sus-
pension has settled.
Tightening torques
ABS pulse sensor to wheel bearing carrier 8
Nrn (6 ft-lb)
Air line connection 2 Nrn (18 in-lb)
Brake rotor to hub 16
Nrn (12 ft-lb)
Driveshaft
CV joint to final drive flange
- MI0 (Torx bolts) 70
Nrn (51 ft-lb)
- MB (compression nut) 32 Nrn (24 ft-lb)
Rear
brake pad carrier (caliper) to wheel 65
Nrn (48 ft-lb)
bearing carrier
Road wheel to hub
120ilO Nrn
(89 i-7 ft-lb)
Rear subframe mounting bushings,
removing and installing
- Remove rear subframe mounting bolts as described earlier.
Lower
subframe approximately 40 - 45 mm (1 -2 in).
4 Install BMW special tools 33 4 140,33 4 151,33 4 154,33 4
155,33 4 156 as shown.
Use hot air gun with a maximum output temperature of
600°C (1100" F) to heat bushing area of subframe for no
more than
2 minutes. Remove rubber mount from sub-
frame.
CAUTION-
Aluminum suspension parts may be severely damaged
witli intense heat
* Heating for 2 minutes with the recommended heat
source is intended to
keep the temperature of the alu-
minum
parts below the safety threshold of 80°C
(1 76°F). .

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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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Final Drive
Final drive input shaft seal, replacing
- Remove exhaust system. See 180 Exhaust System
- Remove drive shaft. See 260 Driveshaft.
< Lift out collar nut locking plate (arrow).
4 While counterholding drive flange with special BMW tool 23
23 0 020 0 020 loosen and remove collar nut.

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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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2 INDEX
Battery, starter, alternator
alternator (generator)
121-10
6-cylinder engine, removingi
installing 121-15
M62 engine 121-16
M62 TU engine (water cooled)
121-18
battery
121-5 charging 121-9
safety terminal 121-3
testing 121-5 charging system, troubleshooting
121-12
starter
121-1 9
6-cylinder engine, removingi instaliinq 121-20 . V-8 engine, rernovinglinsialiing
121-21
solenoid, removinglinstalling
121-23 troubleshooting 121-19
see also Maintenance
Bearing, wheel
see Front suspension
see also Rear suspension
Belts see Maintenance, drive belts
Blade, wiper
see Wipers and Washers
Blower motor see
A/C
BMW emblem
see Exterior trim
BMW special tools 010-18 see also special tools section at
beginning
of each repair group
Body dimensions 400-2
interior features
400-9 salety and security 400-7
Body side molding
see Exterior trim
Bonnet see Engine hood
Boot see Trunk
Brake fluid
020-24, 340-8
Brake fluid pressure sensor
340-30
Brakes
ABS, ASC or DSC system
300-12
component replacement 340-26
ASCIDSC switch
see Switches
bleeding
bralces 340-8
brake booster 340-1 9 bralce Dads. caiioers and rotors ,., 340-1 1
descriotion 300-10
e~ectrdnic brake & stability 300-11
light switch
see Switches
master cylinder
340-16 pariking brake 340-22
troubleshooting 340-5
Bulbs see Lights
Bumper
lront 510-6 height, adjusting 510-12
rear 510-9
Bus system
600-4
Camber
320-33
Camshaft
removingiinslaiiing
M52 engine 116-12
M52 TU
/ M54 engine 116-1 9 M62 engine 11 6-39
wear
116-6
Camshaft position sensors
see ignition system
Camshaft timing chain
adjusting M52 engine
117-22
M52 TU I M54 engine 117-43
M62 engine 117-79 removinglinstalling
M52 engine 117-26
M52TU 1 M54 engine 113-46.116-
28
M62 engine 117-66
Capacities, fluid
020.10
Car rnemorvlicev memorv . . 600-10
see also Centrai
lociking
Carbon canister, activated
see Fuel
tank
Caster
320-33
Catalytic converter and oxygen sensor 020-19
see also Exhaust system: exhaust
manilolds
Cautions
001-3
CD changer
650-4
Center bearing, driveshaft
see Driveshait
Center brake light
sedan
630-13
Center console
513-3
Centrai body electronics (ZKE 111)
600-6
Central locking
car memoryiey memory 515.12 general module iunctions 515-2
remote entry (FZV) 515-8
remote lkey initialization 515-10 single lociddouble ioclk 515-6
switch 515-4
Chain
see Camshaft liming chain
Characteristic map (electrically heated) thermostat
see Electrically heated thermostat
Charging system
see Battery, starter, alternator
Cluster see instruments
Clutch fluid see Maintenance
hydraulics
210-4
mechanical 210-9
switch
see Switches, pedal ciuster
variations
210.10
Codes, fault OED-1
Coil
see Ignition system
Coil spring
see Front suspension
see also Rear
suspe nsion