1999 BMW 540i service

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240-2
/ ~utomatic Transmission
This section covers maintenance and replacement of the
automatic transmission for
E39 models.
Automatic transmission internal repairs are not covered.
Such repairs require special service equipment and knowl-
edge. If it is determined that transmission internal
sewice is
required, consult an authorized BMW dealer about a factory
reconditioned unit or a transmission rebuild.
CAUTION-
ATF does not circulate unless the engine is running. When
towing an automatic transmission vehicle, use a flat bed truck
or raise the rear wheels off the ground.
Special tools
Some special tools are required for the removal and installa-
tion of an automatic transmission on the
E39 BMW models.
While these tools are not absolutely necessary, they are es-
pecially helpful when dealing with the removal and replace-
ment of the torque converter.
4 Engine support bracket
(Tool No. BMW
00 0 200.00 0 208)
4 Transmission jack
(Tool No.
BMW 00 2 030)
4 Engine support block (V-8 models) 11 7310 (Tool No. BMW 11 7 310)

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250-2
I Gearshift Linkage
This repair group covers transmission gearshift and linkage service for both manual and automatic transmission
equipped vehicles.
To gain access to the complete gearshift mechanism it is
necessary to remove the exhaust system and the driveshaft
as described in
180 Exhaust System and 260 Driveshaft.
NOTE-
In models with automatic transmission, the electronic immo-
bilizer
(EWS) prevents starter operation unless the gear po-
sition is Park or Neutral.
Special tools
BMW suggests the use of one special tool in the removal
of the gear shift lever for manual transmission equipped
I I vehicles.
Manual transmission
gearshift linkage
--
4 Gearshift linkage
1. Inner rubber boot
2. Shift lever mounting ring
3. Bushing
4. Shift console
5. Shift lever
6. Selector rod
7. Spacer ring
8. Circlip
9. Dowel pin
10. Locking ring
11. Washer
12. Gear selector rod coupling
13. Locking pin
14. Bushing
4 Sh~fter spanner
(Tool No. BMW
25 1 11 0)
MANUAL TRANSMISSION GEARSHIFT

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................. General ............................ 260-2 Driveshaft. installing 260-10
.................. Special tools ........................ .26 0.2 Flex.disc. replacing 260-1 1
..... Driveshaft description ................. .26 0.3 Center bearing assembly. replacing 260-12
........ Troubleshooting ..................... .26 0.3 Front centering guide. replacing 260-13
Constant velocity
(CV) joint. replacing .... 260-14 Driveshaft Service ................. .26 0.6
Driveshaft. aligning
................... .26 0.7
Driveshaft. removing
................. .26 0.8

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300-8
Suspension, Steering and Brakes - General
Rear suspension Sport Wagon
(EHC with air springs)
Air sprIn9 Shock absorber I
(tiaction strut) arA
(lower control arm) Integral arm 502330210
EHC initiates a control sequence as necessary. The system
offers the following features:
Control system independent from vehicle engine (no en-
gine driven hydraulic pump system)
Individual control of rear wheels
Uneven load identified and compensated for
Uneven road surfaces identified and not compensated for
Automatic control interrupted when cornering
System diagnosable using the
BMW Service Tester (DIS-
plus, GTI, or MoDiC)

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31 0-2
I Front Suspension
This repair group covers the repair and replacement of com-
ponents that make up the front suspension of E39 cars.
Two different types of steering systems are used in the E39
series. 6-cylinder
(5251,5281 and 530i) models are equipped
with a rack and pinion type steering system mounted to an
aluminum subframe.
V-8 (540i) models use a steering gear-
box type system mounted to a steel subframe.
See
300 Suspension, Steering and Brakes-General for a
description of the front suspension and components, as well
as specifications for setting ride height.
CAUTION-
Some E39 models are equipped with aluminum suspen-
sion components. The foiiowing cautions apply:
Due to the chemical and corrosion characteristics of
aluminum, do not bring into contact with battery acid.
* Do not clean with wire brushes with brass or iron bris-
ties. Only use brushes with stainless steei bristles.
Do not expose to flying sparks from grinding/cutting op-
erations.
* Do not subject to steei welding splashes.
Do not expose to temperatures over 80°C (176°F).
even for short periods. Temperatures in painting faciii-
ties are not a problem.
Special tools
Special service tools are required for most of the work de-
scribed in this repair group. In addition to the tools depicted in
the illustrations, avariety of press tools are necessaryfor con-
trol arm bushing replacement. Read the procedures through
before beginning any job.
31 2 210 I < Strut nut socket
(Tool No. 31 2 210)

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31 0-1 8
I~ront Suspension Tension strut bushing, replacing
- Raise car and remove wheel.
WARNING-
Make sure that the caris firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do
not place jack stands under
suspension parts.
- Remove tension strut from car as described earlier.
- Using a service press and appropriate press tools (BMW
special tools 31 2 26112621263 or equivalent), press bushing
out of tension strut.
4 Clean bushing bore and press in new bushing while aligning
mark on bushing with
rnarlt on tension strut (arrows).
CAUTION-
To avoid damaging the new bushing, press only on the outer
steel sleeve during installation.
- Press bushing in so it protrudes equally from both sides of
tension strut.
- Install tension strut as described earlier.
CAUTION-
Tighten the tension strut bushing through-bolt to its final
torque only with car on the ground and the suspension nor-
mally loaded as described earlier.
The front wheel bearings are permanently sealed and require
no maintenance. The bearing is integral with the wheel hub.
The wheel bearing and hub assembly is bolted to the steering
knuckle.
- Raise car and remove front wheel
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place
jack stands under
susoension Darts.
- Unbolt brake caliper and hang to side with stiff wire. Do not
disconnect bralte hose. Remove bralte disc. See
340
Brakes.

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I Steering and Wheel Alignment
This repair group covers steering wheel and column removal
and steering system service, including wheel alignment infor-
mation.
NOTE-
Ignition loclc cylinder replacement is covered in this sec-
tion.
a For information on steering column mounted switches, in-
cluding the ignition switch, see
612 Switches.
Special tools
Some special tools are necessary to carry out the repairs and
adjustments required for steering service and wheel align-
ment. Be sure to read the procedures through before starting
work on the vehicle.
4 Steering shafl retaining ring installation tool
(Tool No. BMW 32
1 090)
4 Bail joint removal tool
(Tool No. BMW 32
1 190)
4 Pitman arm removal tool
(Tool No. BMW 32 2
000)
4 Inner tie rod removal tool
(Tool No. BMW 32 2
110)

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Steering and Wheel Alignment
Steering system warnings and cautions
WARNING -
The BMW airbag system is complex. Special precautions
must be observed when servicing the system. Serious in-
jury may result if system service is attempted by persons
unfamiliar with the BMW
airbag system and its approved
service procedures. BMW specifies that all inspection and
service should be
peiformed by an authorized BMW deal-
e,:
The BMW E39 is equipped with an airbag mounted in
the steering wheel. The
airbag is an explosive device
and should be treated with extreme caution. Always fol-
low the
airbag removal procedure as outlined in 721
Airbag System (SRS).
BMW airbags are equipped with a bacli-up power sup-
ply inside the
airbag control module. A 5 second wait-
ing period should be observed after the battery cable
has been disconnected. This will allow the reserve
power supply to discharge.
Do not reuse self-locking nuts. They are designed to
be used only once and may fail if reused. Always re-
place them with new locliing nuts.
* Do not install bolts and nuts coated with undercoating
wax, as correct tightening torque cannot be assured.
Always clean the threads with solvent before installa-
tion, or install new parts.
Do not attempt to weld or straighten any steering com-
ponents. Always replace damagedparts.
CAUTION--
- Some E39 models are equipped with aluminum suspen.
sion components. The following cautions apply:
Due to the chemical and corrosion characteristics of
aluminum, do not bring into contact with battery acid.
Do not clean with wire brushes with brass or iron bris-
tles. Only use brushes with stainless steel bristles.
Do
not expose to flying sparks from grindinghutting op-
erations.
Do not subject to steel welding splashes.
* Do not expose to temperatures over 80% (176°F).
even for short periods. Temperatures in painting iacili-
ties are not a problem.