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E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 01-17-2010, 06:24 AM
cn90 cn90 is offline
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DIY: 1998 BMW 528i, PARKING Brake Overhaul

DIY: 1998 BMW 528i, PARKING Brake Overhaul

The E39 Parking Brake is notorious for failing after 5-6 years and 60K, so here is the DIY.
Mine was basically useless at 12 years and 105K miles.

I bought the parts from autohausaz.com, however, you can get these parts from other online vendors as well.
- REAR Brake Rotors.....34211164840.....Balo.....$42/each.......Qty = 2/car
- REAR Brake Shoe Set.....34416761292.....Pagid.....$41/set (total 4 shoes/set).....Qty = 1 set/car
- REAR Brake Hardware Set.....34419064019.....TRW-Lucas-Girling.....$16/set.....Qty = 1 set/car
- Optional: Brake Rotor Bolts.....34211161806.....$1.69/each.....Qty = 1 bolt/rotor

TOTAL COST = $140.




GENERAL NOTES:
- OEM Brake Shoes are made by "Jurid", I use "Pagid", result is nice and solid Parking braking effect.
- Budget 1h/side
- At 12 years, 105K miles, the REAR Rotors were warped, the inner drum part has rusted, the brake shoes material has partially fallen off, no wonder I had trouble with the PARKING Brake, which was basically useless. If your REAR rotors are more than 8 years, 80K miles, consider new REAR rotors because resurfacing the drum part (where the brake shoes come in contact with) is difficult and it may cost $15-20 to do it and it does not make sense to re-surface it while a new rotor (BALO brand) is only $42.



- Do this a level driveway, don't even dream about doing this on a sloped driveway! Once the REAR is raised, there is nothing to prevent the car from rolling, other than the chocks on the FRONT wheel!

PROCEDURE:
1. Chock BOTH the Front and Rear parts of the FRONT Wheels!!!



2. Loosen wheel bolts a bit, but do not remove the bolts yet!

3. Jack one side at a time, place Jackstand under subframe.

4. Remove Rear wheel.

5. From the cabin, set car to Neutral and Release Parking Brake Handle.

6. Pull the UPPER part of the Leather Cover (held by 2 plastic clips) to expose the Brake Cable adjusting nuts.
Mine was never touched before by the previous owners, so I left Brake Cable adjusting nuts alone.
If you need to adjust the cable, do a search! The bottom line is when properly adjusted, there is a VERY SLIGHT slack on the cable, i.e., as soon as you pull 1-2 clicks the other end in the Brake Drum should start moving (you need an assistant to help with this). Anyway, look it up.



7. Remove Brake Caliper 16-mm bolts. I use Rubber Hammer helps with the 16-mm wrench to remove these bolts. You may need to use a screwdriver to pry the caliper out of the rotors (pry between the ventilated part of the rotor and the metal part of the caliper).
Then hang the caliper to the Suspension Spring using electrical wire to prevent straining the brake hose!



8. During re-installation of Brake Caliper. I also use Rubber Hammer on the wrench because it is impossible to get a torque wrench in there.

9. Use a 6-mm Allen wrench to remove the bolt holding the rotor. Adjust the Star Wheel to release the shoes. So read this carefully:
* RIGHT Side: Move Star Wheel DOWN to EXPAND the Brake Shoes.
* LEFT Side: Move Star Wheel UPWARD to EXPAND the Brake Shoes.

Then pull old rotor out.

10. Now pause and observe the existing layout! This is crucial for re-assembly.
- Use a 5-mm Allen Key to twist the pin holding the shoes. The pin uses 90 degrees turn to lock and unlock.



- I use a pair of vice-grip to remove/install the spring (wear eye protection!), basically biting on the straight part of the hook and pull it in or out. You can also use the "special brake spring tool" ($10-15 at local auto parts store).
- BIG Spring goes on TOP and SMALL Spring at Bottom
- Adjusting Star Wheel faces REARWARD.



11. I greased the Brake Cable end with wheel bearing grease using a BBQ skewer:



12. Also clean the Adjusting Star Wheel interior and apply small amount of grease.

13. During re-installation, follow this sequence (I learned it the hard way, so don't asků....hehe!):



14. To adjust the Parking Brake (This is very standard in virtually all cars, so you can also use this idea on a Volvo, Toyota etc.):
- Make sure car is in Neutral and the Parking Brake Handle in the cabin is released. Spin the rotor a bit to be sure it spins freely.
- Re-install the Wheel with only 4 bolts and hand-tighten the bolts snug.
- Move the Wheel Empty Hole so it lines upat approx. 6 o'clock position.
- Use a flash light to shine inside to see the Adjusting Star Wheel.
- Using a small flat screwdriver, TIGHTEN the Star Wheel until the Wheel stops moving.
- Now back off about 5 clicks on the Star Wheel: now you should be able to spin the wheel.
You will hear a slight dragging noise, this is normal, so don't worry about this slight dragging noise!
- Go to the cabin and pull the Parking Brake, it should stops at about 5-6 clicks or so.

15. Remove Jackstand and lower car. Don't forget to torque the Wheel Bolts properly!

16. To seat the shoes, find a quiet street and apply the Hand Brake a few times. I used this Nissan procedure for break-in. It works for virtually any car:



17. Make it a habit using the Parking Brake every time you park the car.

18. Once a month, apply hand brake while driving at 15 mph for about 200 feet (10-15 seconds or so) to prevent rust inside the drum. Anyway, this is what I have been doing for 20 years, right or wrong I don't know, but it works....


Enjoy your brand new Parking Brake!
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Last edited by cn90; 01-17-2010 at 07:34 PM.
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  #2  
Old 01-17-2010, 06:45 AM
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Fudman Fudman is offline
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Another great cn90 DIY!! THANX!
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  #3  
Old 01-17-2010, 08:20 AM
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Quote:
Originally Posted by cn90 View Post
Adjust the Star Wheel to release the shoes. So read this carefully:
* RIGHT Side: Move Star Wheel DOWN to EXPAND the Brake Shoes.
* LEFT Side: Move Star Wheel UPWARD to EXPAND the Brake Shoes.
Thank you cn90! You are so wonderful!

I wish I had this parking brake DIY two years ago when I gave up on replacing my parking brake shoes for lack of a DIY! The Bentleys were useless for me for the parking brake - and there wasn't a DIY that I could find - so I left them alone.

Nowhere does it even say which direction of the star wheel does what (you did! Thanks). It's not obvious which direction does what until you've moved the star adjuster wheel a LOT of clicks and by then, you might hopelessly have misadjusted them (ask me how I know); so, precise details like those you put in your DIY are fantastic timesavers!

Your DIY above will help everyone!

One question I have left over from a rear wheel brake replacement was the thickness measurement wear limit for the parking brake shoes.

I realize your brakes weren't holding so you knew to replace them; but for me, I was wondering if mine were getting close to the wear limit. But I couldn't find the wear limit anywhere (surprisingly).

Does anyone have a figure for the parking brake shoes wear limit?

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File Type: pdf zeckhausen.com_E39_BMW_Rear_Install.pdf (977.6 KB, 372 views)
File Type: pdf cracking_the_brake_edge_codes.pdf (91.4 KB, 351 views)

Last edited by bluebee; 01-18-2010 at 09:00 PM.
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  #4  
Old 01-18-2010, 08:06 AM
cn90 cn90 is offline
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Follow-up,

Over the last few days, I have done the break-in procedure for the Brake Shoes and the Parking Brake holds the car nicely on a slope with car in Neutral; however if you park the car, use BOTH the Parking Brake and 1st Gear for Man Trans cars.

I really like this Pagid Brake Shoes. FYI, OEM is Jurid.

I have been using Pagid brand in all of my Volvo for 20 years, I love it.
Highly recommend Pagid.
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Old 01-18-2010, 12:22 PM
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doru doru is offline
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Very nice Cam.
You da' man. I know I will do those soon (although they still hold up on mine).

Thanks
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  #6  
Old 01-18-2010, 12:29 PM
cn90 cn90 is offline
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Quote:
Originally Posted by bluebee View Post
...Does anyone have a figure for the parking brake shoes wear limit?

Bluebee,

As you indicated that new material is about 3.5-4 mm (0.137") thick.
I'd think 1 mm is the absolute minimum for drum shoes, this is based on the usual recommendation with regular disc brake pad min spec is 1-2 mm.
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Old 01-18-2010, 09:27 PM
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Quote:
Originally Posted by cn90 View Post
new material is about 3.5-4 mm (0.137") thick.
I'd think 1 mm is the absolute minimum for drum shoes
Thanks cn90! This is GREAT to (finally) have a minimum thickness for brake shoes!
* Nominal thickness (new) ~= 0.240 inches (shoe + plate)
* Minimum thickness (old) ~= 0.140 inches (shoe + plate)


Here's how I came up with that:
Given that every 1mm is about 0.0394 inches and given the thickness of the steel backing plate on my E39 was 0.1005 inches, the minimum measured thickness of the backing plate + friction material calculates to 0.0394 + 0.1005 which comes to just about 0.1400 inches.

If new brake shoe friction material is 0.137" thick, then with a 0.1005" backing plate, the nominal new thickness is 0.2375 which I'll round up to 0.240 inches.

Note: Since my brake shoes were 0.2375 inches thick (pad + steel), which is no where near 140 thousandths of an inch, I was right not to replace the brake shoes at the time I measured them. Interestingly, it seems my brake shoes, at 238 thousandths of an inch must have been almost new (based on cn90's statement that new material is about 0.137" thick.

This picture is from the attached E36 brake job DIY which included parking brake shoes.
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Last edited by bluebee; 01-18-2010 at 09:48 PM.
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Old 01-19-2010, 06:50 AM
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Any ideas for replacing the bowden cables? I can't manage to get the plug out of the rear of the wheel carrier.
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  #9  
Old 01-19-2010, 07:16 AM
cn90 cn90 is offline
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Any ideas for replacing the bowden cables? I can't manage to get the plug out of the rear of the wheel carrier.
Look behind the Brake Shield for items #7 and 8:

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Old 01-19-2010, 07:57 AM
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Al's540i Al's540i is offline
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Excellent CN! I imagine the same procedure can be performed on a 540?

I've adjusted mine several times in the past, but when on a slope and I pull the brake handle and let go, the car moves down a tad before engaging. Irritates the hell out of me. Perhaps my shoes are shot???
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Last edited by Al's540i; 01-19-2010 at 08:03 AM.
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Old 01-19-2010, 08:46 AM
cn90 cn90 is offline
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Quote:
Originally Posted by Al's540i View Post
Excellent CN! I imagine the same procedure can be performed on a 540?

I've adjusted mine several times in the past, but when on a slope and I pull the brake handle and let go, the car moves down a tad before engaging. Irritates the hell out of me. Perhaps my shoes are shot???
Yes, your shoes are gone.

Procedure is the same for 540 (I don't know about M5).
Part Numbers are the same for 540.

1. Brake Rotor 34211164840 is the same as 34216767060 (which is listed for V8). Both of these PNs are the same.
http://eactuning.com/ssf/part_number_search/34211164840

http://www.rmeuropean.com/search.asp...rd=34211164840

2. Brake Shoes PN is the same.

Check realoem.com to be sure. You will be happy you do this.

Off topic, but my next project (rear suspension) is on hold because I just sent some 500 bones to Red Cross to help the earth-quake victims in Haiti. I might even go there soon.

Last edited by cn90; 01-19-2010 at 09:04 AM.
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Old 01-19-2010, 09:11 AM
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Quote:
Originally Posted by cn90 View Post
Yes, your shoes are gone.

Procedure is the same for 540 (I don't know about M5).
Part Numbers are the same for 540.

1. Brake Rotor 34211164840 is the same as 34216767060 (which is listed for V8). Both of these PNs are the same.
http://eactuning.com/ssf/part_number_search/34211164840

http://www.rmeuropean.com/search.asp...rd=34211164840

2. Brake Shoes PN is the same.

Check realoem.com to be sure. You will be happy you do this.

Off topic, but my next project (rear suspension) is on hold because I just sent some 500 bones to Red Cross to help the earth-quake victims in Haiti. I might even go there soon.

Wow, your a good guy CN!

My rear suspension will be done this Saturday by my Indie. Going OEM Sachs. Eventually I'll get the fronts done as well.
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Old 01-19-2010, 09:47 AM
cn90 cn90 is offline
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Quote:
Originally Posted by Al's540i View Post
Wow, your a good guy CN!

My rear suspension will be done this Saturday by my Indie. Going OEM Sachs. Eventually I'll get the fronts done as well.
Al,

While in there doing the REAR suspension, your indy may want to tackle the Parking Brake issues too.
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Old 01-19-2010, 12:57 PM
cn90 cn90 is offline
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I forgot to mention the proper use of the Brake Plier. It is mentioned at time marking of 0:40 in this clip found on youtube, basically the pliers squeeze between the shoe and the spring to hook it in place:

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Old 01-20-2010, 07:14 AM
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Quote:
Originally Posted by cn90 View Post
At 12 years, 105K miles, the REAR Rotors were warped
One minor question that's actually OT for the brake shoes (which is a wonderful DIY that I wish I had two years ago!). I don't mean to take away from this thread so you can answer quickly and I won't argue.

But ... I'm curious ... because ... information has it ... most times what we think of as "warped" is not warped at all ...

Are you sure the brake rotors warped?
(See details on warp, shudder, and rebedding ... )

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Old 01-20-2010, 07:40 AM
cn90 cn90 is offline
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Bluebee,

The issue of brake pad deposit on the rotor has been discussed multiple times here.

Brake Pedal pulsation is caused by many factors:

- Uneven rotor surface friction coefficient (which may be caused by pad deposit, especially when applying brake pedal when rotor is HOT).

- Warped rotor DOES exist. When I removed my old rotor, it was deeply scored with grooves.

- Another issue is resurfacing the rotor or not. Back in the old days, rotors were more expensive so resurfacing is recommended.
Now, a new rotor is about $40-50 (Resurfacing cost is about $10-20). So the incentive to resurface is less now.

But for the sake of argument, regardless of the causes of brake pedal pulsing, whether it is pad deposit or warped rotor) resurfacing rotor helps smooth things out, but as you know the rotor is now thinner after resurfacing, so it may be warped again sooner than a brand new rotor.

In my experience, resurfacing helps.

This is good reading for everyone.
http://www.tomorrowstechnician.com/A...rakes_101.aspx

Last edited by cn90; 01-20-2010 at 07:47 AM.
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Old 01-20-2010, 10:17 PM
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The issue of brake pad deposit on the rotor has been discussed multiple times here.
OK. I was just curious. I said I wouldn't argue.

Interestingly, when I read the reference article, this one sentence stuck out because of what wasn't said.

"In some states, such as California, the law stipulates when certain parts may or may not be replaced."


Hmmm. Anyone know what the California law stipulates with respect to front and rear and parking brake parts? I found the CA BAR web page but it doesn't say.

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Old 11-18-2010, 07:41 AM
cn90 cn90 is offline
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This is another reason to keep you Parking Brake in Top Shape!
In extreme situation when you have Total Hydraulic Failure, the Parking Brake is the ONLY "Last Line of Defense"!

In this thread, this E39 car just kept going and going (I assume a Total Brake System Failure). Don't know the exact cause but this was what happened!
http://forums.bimmerforums.com/forum...php?p=20742478
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Old 01-07-2011, 04:40 PM
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Getting ready to do this...
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Old 01-07-2011, 05:20 PM
bmw_lover85 bmw_lover85 is offline
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Awesome write up
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Old 01-09-2011, 08:01 PM
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Part number 34419064019 was superseded by part number 34410304724.
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Old 01-09-2011, 08:21 PM
cn90 cn90 is offline
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Part number 34419064019 was superseded by part number 34410304724.
Thanks Jason!

It is interesting to see the new PN but the parts are exactly identical.
I just checked different websites and it shows the same hardware kit.
Does anyone know when a part is superceded with a new PN, what does it mean besides a different PN?
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Old 01-09-2011, 08:26 PM
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Originally Posted by cn90 View Post
Thanks Jason!

It is interesting to see the new PN but the parts are exactly identical.
I just checked different websites and it shows the same hardware kit.
Does anyone know when a part is superceded with a new PN, what does it mean besides a different PN?
I have been checking on prices.
I happened to check Tischer/ GetBMWparts.com , put in the part number from your DIY, and their site told me it was an old part number.
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Old 01-09-2011, 08:36 PM
cn90 cn90 is offline
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Hi Jason,

I am just wondering about the logistic of any PN when superseded, what it means. Just a general question on any part, not just this Parking Brake part.
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Old 01-10-2011, 09:10 AM
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Quote:
Originally Posted by cn90 View Post
Hi Jason,

I am just wondering about the logistic of any PN when superseded, what it means. Just a general question on any part, not just this Parking Brake part.
I don't know how BMW makes the decision.
Based on my experience in industrial settings, the superseding part is changed in some manner but:
1 is backward compatible for use in the old application, old stock can be used in its original application, but not in a new application/machine/equipment. Instance 1 is most common when the part is used in a new application/machine that needs different properties. Sometimes when the new part has been redesigned for cost reduction and looks different even though it will perform the same function. Superseding reduces the number of stock units to inventory which is a cost saving.

or

2 the old part # should not be used any longer & old stock will be withdrawn from the supply chain. Instance 2 would usually occur when experience demonstrated that the original part fails prematurely or is found not to perform properly under conditions overlooked during design.

Instance 1 vs 2 is often invisible to the end users. The OEM decides whether to actively withdraw superseded stock from the supply chain or let it run down without replenishment.

This explanation is simplified, but I'm trying to avoid a treatise in engineering change management, inventory control and supply chain management .

Regards
RDL
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