I've updated the repair list to the following (almost all of which I've experienced). Let me know if anything is missing ...
See also:
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Typical SYMPTOMS that point to a classic E39 problem?
Common problems you can expect with your E39 might be:
- plastic expansion tank, radiator, & thermostat housings that blow up due to faulty plastic mostly at the upper hose neck but also in the expansion tank and thermostat housing (
1)
- steel resistance-welded ABS control module power wires that break off their gold contact because of being too close to the engine (
1) (
2) (
3) ... Abs control module autopsy (
1) (
2) ... why the diagnostic tools fail (
1)
- I6 vanos seals made out of the wrong materials so that they harden and leak causing degrading performance (
1)
- V8 valley pan ???
- headlight adjusters that simply crumble over time causing the lights to point downward (
0) (
1) (
2) (
3) (
4) (
5) (
6) (
7) (
8) (
9) (
10) (
11) (
12)
- fan-control (FSU/FSR) modules that are practically sure to go schizo due to poor heat-sink design (
1) (
2) (
3) (
4) (
5) (
6) (
7) ... Autopsy (
1) (
2) (
3) (
4)
- rear vapor barrier seals that allow rain water to fill the rear footwell (
1) (
2) (
3) (
4) (
5) (
6)
- windshield & back window molding that crumbles in three years due to poor choice of materials (
1) (
2)
- jack pads that fall off the underside of the frame due to poor latch design causing jack failures & wind noise (
1) (
2) (
3)
- cabin-filter housing design that allows small drain hoses to clog with leaves causing gym-sock smells (
1) (
2) (
3)
- roundels that wash away in the car wash over time (
1)
- a trunk loom wiring harness designed to chafe causing all sorts of light and fuse blowing and locking problems (
1) (
2)
- violent shudder upon front-wheel braking on bumps because the front suspension dies prematurely unbeknownst to the driver (
1) (
2) (
3) (
4) (
5) (
6)
- rear-window regulators that stop the windows from closing
(1) (2) (3) (
4) (
5) (
6) (
7) (
8) (
9) (
10) (
11) (
12)
- low mounted ambient temperature sensors practically designed to be ripped off on a parking curb (
1) (
2) (
3) (
4) (
5)
- annoying automatic door-lock mechanism that cost $100 to undo (
1) (
2)
- pixels practically guaranteed to go out on your instrument cluster and radio midi (
1)
(2) (
3) (4)
- useless cupholders and painful front armrest consoles (
1)
- constantly wet power steering reservoirs due to poor O-ring design (
1) (
2)
- power steering hose clamps practically guaranteed to leak (
1) (
2)
- wood trim whose varnish cracks and whose cd cover doors rattle (
1) (
2) (
3)
- plastic trim around the air vents which invariably crack at the corners (
1)
- seat covers that don't protect the control box for the tilting steering and moving seat (
1)
- seat cables that fall out causing seat twist
(1) (2) (3) (4) (5) (6) (7) (8)(
9)
(10)
- windshield reservoirs prone to leaking due to an ill-fitting pump o-ring gasket (
1)
- crankcase ventilation valve (CCV) clogs, raising pressures, blowing the head gasket and/or valve cover gasket (VCG) and oil filter housing (OFH) gasket & causing vacuum leaks (
1) (
1) (
2)
- the secondary air pump (SAP) valve (aka diverter valve) clogs, taking out the SAS
(1) (
2) (3) (4)
- ignition switch that fails causing electrical problems (
1) (
2) (
3) (
4) (
5) (
6) (
7) (
8)
- the mass air flow sensor (MAF) and idle control valve (ICV) require periodic cleaning (
1) (
2)
- poorly designed V8 valley pan gaskets that leak coolant (
1) (
2)
- fluid-filled thrust arm bushings that crack and tear causing vibrations at speed (
1) (
2) (
3) (
4)
- before your alternator goes bad on you, buy the rebuild parts AHEAD of time so you get QUALITY components (
1)
- anything else?