1999 BMW 528i Suspension

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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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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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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.

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340-1 2
Brakes Brake pads, checking and replacing
Brake pads can be replaced without disconnecting the brake
fluid hose from the caliper or having to bleed the brakes. The
rotors can be replaced without disassembling wheel hub and
bearing. Always machine or replace rotors in pairs. Replace
pads in sets.
Front and rear brake pad replacement procedures are identical.
WARNING -
* Altllough semi-metallic andmetallic brale friction materials
in brake pads or shoes no longer contain asbestos, they
produce dangerous dust.
Treat all
brale dust as a hazardous material.
Do not create dust by grinding, sanding, or cleaning
brake friction surfaces with compressed air.
CAUTION--
Pressing caliper piston in may cause brake fluid reservoir to
overflow To prevent this, use a clean syringe to first remove
some fluid
from reservoir.
Raise car and remove wheels,
WARNING-
Make 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.
/ 4 To measure brake pad lining thickness, insert BMW special
n 1 tool 34 1 260 at either frontilght wheel or left rear wheel -
Move wheel until notch for brake wear indicator can be
seen through wheel opening.
Insert tip of tool into notch so that the body of tool rests on
brake pad backing plate
(A), and tip touches bralte disc
(B).
Replace pads if thickness is 3.0 mm (0.12 in) or less.
Pry off
bralte calipe~ , anti-rattle spring (arrow).

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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.

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340-23
Brakes
- Using flat-bladed screwdriver, reach into brake drum through
lug bolt hole. Turn brake adjuster until wheel no longer turns.
Back adjuster off
12 notches.
Parking brake adjusting (initial)
Back
off adjuster through wheel
lug bolt hole 12 notches
- Working inside car, set parking brake several times to seat
cable. Then pull parking brake
lever up two notches. Tighten
cable adjusting nuts until it is just possible to turn rear wheels
with slight resistance.
- Release lever and make sure rear wheels turn freely
- Turn on ignition. Pull up parlting brake lever 1 notch and
make sure that parking bralte warning light comes on. if not,
adjust parking bralte warning light contact switch.
- Install parking brake lever boot. Install road wheel lug bolts.
Tightening torque Road
wheel to hub 120 i. 10 Nrn (89 i- 7 ft-lb)
Parking brake shoes, removing and
installing
- Raise rear of car and remove road wheels.
WARNING-
Make 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
jaclc stands under suspension
parts.
- Without disconnecting brake fluid hose, remove rear bralte
calipers from trailing arms. Remove rear brake rotors as de-
scribed earlier.
CAUTION-
Do not let the brake caliper assembly hang from the brake
hose. Support caliper from chassis with strong wire.
4 Unhook return sprlngs (arrows) from brake shoes