1999 BMW 525i Workshop Manual

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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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This repair group covers brake service:
Brake pads, calipers, and disks
Master cylinder, bralte booster, and parking brake
ABS
1 ASC and ABS / DSC component replacement
ABS
1 ASC and ABS 1 DSC system descriptions are covered
in
300 Suspension, Steering and Brakes - General.
Special Tools
BMW requires the use of either the DIS or the MoDiC diag-
nostic tool to safely and completely bleed the
brak~ng and
traction control systems. Read all procedures through before
beginning a job.
< Parking bralte cable adjusting tool
(Tool No. BMW 34
1 030)
4 Brake piston expander
(Tool No. BMW 34
1 050)
4 Bralte caliper bolt tool (7 mrn Allen)
(Tool No. BMW 34
1 080)
34 I 000
34 1 090 < Steel wire brush
7 (Tool No. BMW 34 1 090)

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, Brake caliper bolt tool
4 ASC bleeder wrench
(Tool No. BMW 34
3 110)
4 Brake line flare wrench set (12 mm, 14 mm, 17 mm, 19 rnm)
(Tool No. BMW 34 3 150)
34 3 152
34 3 153
34 3 154
4 DSC Dressure sensor installation socltet
4 ABS IASC or ABSI DSC control unit 42-pin harness adapter
(break-out adapter)
(Tool No. BMW 34 5 240)
0
(Tool NO. BMW 34 5 160)

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E39 brake system
BMW E39 models are equipped with vacuum power-assisted
four-wheel disc brakes with an integral
Antilock Brake System
(ABS). Single-piston calipers act on vented front and rear ro-
tors. A brake pad wear sensor for each axle indicates when
brake pads need replacement. The dual drum-type parking
brake system is integrated with the rear brake rotors.
Electronic braking and stability control
E39 models were introduced with Automatic Stability Control,
a computer controlled traction control system that uses the
AB5 system in conjunction with engine management controls
to control wheel spin during take-off and maintain vehicle sta-
bility while braking.
Added in the
1998 model year was Dynamic Stability Control
(DSC). This system implements wheel speed modulation
throughout all stages of driving. For example, DSC is able to
reduce understeer by applying differing amounts of braking
force to each wheel, or it can override the engine manage-
ment system during hard cornering.
A summary of distinguishing characteristics of the various
systems is shown in the table
E39 electronic braking and
stability control systems.
For ABS, ASC and DSC system and component descriptions,
see
300 Suspension, Steering and Brakes-General.
WARNING-
A car with electronic stability control is still subject to normal
physical laws. Avoid excessive speeds for the road conditions
encountered.
E39 electronic braking and stability control systems
Year (model)
manuf. up to 911998
(528i, 540i)
manuf. from 911999
(540i optional)*
From
911 999
(ail models) System
Automatic Stability Control (ASC) Identifiers
Electronic control module next to glove compartment
Hydraulic unit in right rear of engine compartment
No precharge pump
Dynamic Stability Control
(Bosch DSC
Ill v. 5.3)
Dynamic
Stabil~ty Control
(Bosch DSC
Ill v. 5.7) Electronic
control module next to glove compartment
Hydraulic unit in right rear of engine compartment
Precharge pump in left front of engine compartment, below steering
fluid reservoir
Separate rotational rate (yaw) and lateral acceleration sensors
Control
modulelhydraulic unit in right rear of engine compartment
No precharge pump
Combined rotational rate (yaw) and lateral acceleration sensors

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Brakes
Troubleshooting
Brake performance is mainly affected by three things:
Q Level and condition of brake fluid
Ability of bralte system to create and maintain pressure
Condition of friction components
Air in bralte fluid will
make the brake pedal feel spongy during
braking
orwill increase the bralte pedal force required to stop.
Fluid contaminated by moisture or dirt can corrode the sys-
tem. lnspect the brake fluid inside the reservoir. If it is dirty or
murky, or is more then two years old, replace fluid.
To
check the function of the master cylinder hold the bralte
pedal down hard with the engine running. If the pedal slowly
falls to the floor, either the master cylinder is leaking internal-
ly, or fluid is leaking externally.
lnspect the rotors for glazing, discoloration and scoring.
Steering wheel vibration while braking at speed is often
caused by warped rotors, but can also be caused by worn
suspension components.
When troubleshooting, keep in mind that tire inflation, wear
and temperature can all have an affect on braking. See
300
Suspension, Steering and Brakes-General for additional
suspension and brake system troubleshooting.
The table Brake system troubleshooting lists symptoms of
brake problems, probable causes, and suggested corrective
actions. Unless noted otherwise, relevant repairs are de-
scribed later in this repair group.

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340-6
1 Brakes
Brake system troubleshooting
/symptom I Probable cause 1 Repairs
Brake squeal
Pedal goes to floor when
bralting
Low pedal after system bleeding
Pedal spongy or brakes work
only when pedal is pumped
Excessive braking effort
Brakes pulsate, chatter or grab
Uneven
bralting, car pulls to one
side, rear braltes
loclt
Brakes drag, bind or overheat Brake
pad carriers dirty or corroded or
pads loose (poor fit) in pad carrier
Braite pads heat-glazed or oil-soaked
Wheel bearings worn (noise most
pronounced when turning)
Incorrectly Installed brake pads,
parking bralte shoes, or bralte parts
Brake fluid loss due to system leaks
Master cylinder or traction control
system faulty
Master cylinder faulty
Air in braite fluid
Master cylinder or traction control
system faulty
Brake pads wet
Brake pads
heat-glazedorfluid-soalted
Vacuum booster or vacuum hose
connections to booster faulty
--- Warped brake rotors
Brake pads worn
Brake pads heat-glazed or oil-soaked Remove
brake pads and clean calipers. Use original
equipment pads for proper fit and use BMW anti-squeal
compound during installation,
Replace brake pads. Ciean rotors. Replace leaking caliper:
as required.
Replace worn bearings. See 310 Front Suspension
or33C
Rear Suspension.
Check component installation. Checldreplace anti-rattle
springs.
Checlt fluid level and inspect for signs of leakage.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Replace master cylinder.
Bleed system using factory or compatible diagnostic tool.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Use light pedal pressure to dry pads while driving.
Replace
bralte pads and rotors. Replace leaking calipers.
lnspect vacuum lines. Test vacuum booster and replace as
required. Test vacuum non-return valve for one-way flow.
Resurface or replace rotors.
Replace brake pads.
Clean rotors. Replace leaiting calipers.
Incorrect tire pressures or worn tires
Brake pads on one side of car heat-
glazed or fluid-soaked
Caliper or brake pads binding
Worn suspension components
Brake caliper or brake pads binding
Master cylinder or traction control
system faulty lnspect
tire condition. Checlt and correct tire pressures.
Replace brake pads. Clean rotors. Replace leaking
calipers.
Clean and recondition brakes.
Inspect for worn or damaged suspension components. See
310 Front Suspension or 330 Rear Suspension.
Ciean or replace caliper.
Replace master cylinder. Diagnose traction control system
using faclory or compatible diagnostic tool.