2001 BMW 525i 20 pin

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331-2
Final Drive
This repair group covers removal and repair informat~on for
the final drive (differential), axle shafts.
CV joints, CV joint
boots, and final drive seal replacement.
Internal repairs of the differential assembly are not covered in
this manual.
Special tools
BMW recommends some special tools for the removal of the
drive axles as well as the installation of rear differential input
and output drive flange seals. Some common pullers and
drifts can often be substituted for these tools.
4 Drive flange holder
(Tool No. BMW
2 30 020)
< Drive flange puller
(ToolNo.BMW31 2101 131 2102131 2103131 2104)
< Drive pinion set
(Tool No. BMW 33 1 340)
4 Clamp~ng tool set
(ToolNo.BMW332101 13321021332103)

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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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331-17
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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, 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
Brakes, bleeding
The procedure below requires a BMW Service Tester (DIS-
pluslGTl/MoDiC).
- Determine type of traction control (ASC, DSC with precharge
pump, DSC without precharge pump). Be sure to use correct
specification brake fluid, according to application table below.
Brake fluid applications
ABS I ASC and ABS / DSC models DOT 4 brake fluid
with precharge pump (to 911998)
ABS I DSC models without precharge DOT 4 low viscosity
pump (911998 and later) brake
fluid
< Remove left side interior ventilation microfilter housing:
Remove upper cover and microfilter loclting clip
(A).
Release locking clamp (B), and rotate air tube in direction
of arrow to remove.
Disconnect wiring harness from hood switch
(C).
Release filter body mounting clamp (D) and remove lower
microfilter housing.
- Top off bralte fluid in reservoir and connect BMW Service
Tester to
20 pin Data Link Connector (DLC) under hood or 16
pin
DLCIOBD I1 connector under dash.
- Call up service function Bleeding ABS / ASC or service func-
tion Bleeding ABS
/ DSC, depending on installed system.
- Fill pressure bleeding device with the correct brake fluid and
connect to brake fluid reservoir and apply pressurize.
Do not exceed a pressure of
2 bar (29 psi) when pressure
bleeding the
brake system. Excessive pressure will damage
4 Starting at right rear wheel, connect bleed hose and fluid re-
ceptacle to bleeder screw (arrow).
CA UTlON-
Bleeder hose must always remain submersed in clean brake
fluid whenever the bleeder valve is open.

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1 Brakes
Pull down panel
If applicable, disconnect electrical harness
rows) from 16-pin OBD-ll plug.
Remove panel from interior. connectors
(ar-
Working
above and in front of pedals, remove locking clip (A)
and slide brake booster pushrod off bralte pedal pin. Remove
brake booster mounting nuts
(6).
Working in engine compartment, carefully separate bralte
booster from engine compartment bulkhead.
CAUTION-
Do not use force on booster when separating from bulkhead.
This can damage booster and pushrod.
Remove booster by tilting out in direction of engine. Lift
booster up and out of engine compartment.
- Installation is reverse of removal, noting the following:
Make sure all nuts, fluid couplings, thread bores and mat-
ing surfaces are clean.
Replace bralte booster self-locking mounting nuts.
Replace sealing O-ring between master cylinder and bralte
booster.
Bleed bralte system as described earlier.
CAUTION--
Do not over-torque tlie master cylinder mounting bolts.
This could damage the
bralce booster and prevent proper
vacuum build-up.
After
30 minutes of use recheclc the torque on bralce
booster mounting nuts.
Tightening torques
Brake master cylinder to brake booster
26 Nm (19 it-lb)
Brake booster to bulkhead 22 Nm (16 it-lb)
(Recheck torque after
30 minutes of use.)
Brake fluid line to master cylinder 18 Nm (13 it-lb)
NOTE-
When replacing the brake booster check valve or vacuum
hose, install the valve so that the molded arrow is pointing to-
ward the
fntalce manifold. Use new hose clamps

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Brakes
Parking brake components
1. Clamp
2. Parking brake cable
3. Cable bracket
4. Grommet
5. Adjusting screw
6. Support
7. Shoe expander
8. Return springs
9. Parking brake shoe
10. Lock down spring
11. Shoe retaining pin
12. Adjuster
Parking brake, adjusting
The parking brake is a brake drum system integrated into the I
rear brake rotors. It can be adjusted with the wheels installed,
although the rear wheels will have to be raised off the ground.
- Adjusting the parking bralte becomes necessary under the
following circumstances:
After replacing parking bralte shoes
After replacing rear brake rotors
Excessive stroke of parking brake handle required for ac-
tuation (more then
10 clicks)
After replacement of brake shoe adjuster or parking bralte
cable(s)
- Lift parking brake lever boot out of console. While holding ca-