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E60 / E61 (2004 - 2010)
BMW 5-Series E60 Sedan was first seen in the Unites States in the fall of 2003 with a 2004 Model Year designation. The E61 wagon followed shortly there after. The E60/E61 5 series is now available as a 528i, 528xi, 535i, 535xi, 550i and a 535xi sports wagon! -- View the E60 Wiki

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  #1  
Old 08-16-2016, 11:21 PM
TX550 TX550 is offline
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Active Roll Bar Bushings

Have any of you all gotten noise coming from the two ARS bushings and if so, did you all replace them? I've been getting a creaking sound on left turns and my indy and I could not figure out what it was.

In process of looking for the noise, I discovered that the subframe that I had replaced in March of 2015 for cracked welds is cracked again It's going into the dealership on Thursday to have that rectified. If they don't give me issues with repairing the work that they warranty, I'm going to have them replace the bushings as well to see if that fixes the noise.
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Old 08-17-2016, 08:11 AM
jim165 jim165 is offline
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Originally Posted by TX550 View Post
Have any of you all gotten noise coming from the two ARS bushings and if so, did you all replace them? I've been getting a creaking sound on left turns and my indy and I could not figure out what it was.

In process of looking for the noise, I discovered that the subframe that I had replaced in March of 2015 for cracked welds is cracked again It's going into the dealership on Thursday to have that rectified. If they don't give me issues with repairing the work that they warranty, I'm going to have them replace the bushings as well to see if that fixes the noise.
I'm kinda diverting from the main issue, and I apologize, but did you notice any change in driving characteristics with the broken subframe? It seems like you weren't aware that was broken again without looking at it, so no change in the way it drives? Mine could be broken and I wouldn't know it...
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Old 08-17-2016, 11:32 AM
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As far as I could tell, there was no appreciable difference in driving characteristics. The only thing that was happening was the constant creaking.
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Old 08-17-2016, 02:12 PM
jim165 jim165 is offline
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As far as I could tell, there was no appreciable difference in driving characteristics. The only thing that was happening was the constant creaking.
Thanks for the input. Concerning your problem, though....I've never heard of any issues with the ARS bushings causing noise. Usually it's worn suspension bushings or possibly the strut tower brace bolts on the firewall being loose that cause most groans, sqeeks, creaks, and knocks (in my case).

Last edited by jim165; 08-17-2016 at 02:15 PM.
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Old 08-17-2016, 02:36 PM
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Originally Posted by TX550 View Post
Have any of you all gotten noise coming from the two ARS bushings and if so, did you all replace them? I've been getting a creaking sound on left turns and my indy and I could not figure out what it was.

In process of looking for the noise, I discovered that the subframe that I had replaced in March of 2015 for cracked welds is cracked again It's going into the dealership on Thursday to have that rectified. If they don't give me issues with repairing the work that they warranty, I'm going to have them replace the bushings as well to see if that fixes the noise.
Subframe cracked again? Any idea as to what causes the crack?

How many miles are you currently at?
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Old 08-18-2016, 10:50 AM
TX550 TX550 is offline
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Originally Posted by jim165 View Post
Thanks for the input. Concerning your problem, though....I've never heard of any issues with the ARS bushings causing noise. Usually it's worn suspension bushings or possibly the strut tower brace bolts on the firewall being loose that cause most groans, sqeeks, creaks, and knocks (in my case).
My indy and I went over all of those things and more. We ran the ARS system check from his computer and the noise appeared every time the vehicle tilted to the right so it most definitely something with the ARS; either the cracked weld, the bushings or the ARS itself is the culprit.
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Old 08-18-2016, 04:25 PM
jim165 jim165 is offline
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My indy and I went over all of those things and more. We ran the ARS system check from his computer and the noise appeared every time the vehicle tilted to the right so it most definitely something with the ARS; either the cracked weld, the bushings or the ARS itself is the culprit.
Damn, always something with these crappy-ass cars. Well, I've had my entire ARS assembly replaced due to excessive leaks, so I guess anythings possible. Good luck...
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Old 08-18-2016, 04:42 PM
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I hear a creaking sound in the front right above my head unit but it's not on turns tho mostly on speed bumps is this the same sound ?? Or it just my dashboard is old by the year of my car... :-/
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Old 08-18-2016, 04:45 PM
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Originally Posted by 07 E63650i View Post
Subframe cracked again? Any idea as to what causes the crack?

How many miles are you currently at?
The first time around, I honestly don't know what cracked it. There were not any impacts to the subframe itself. I'm currently at 150,000 miles. This time around, after talking with the dealer today and looking at the car on the lift with the tech, we found an extremely loose bolt on the top, driver side stabilizer support/retaining bracket. The loose bolt coincides with where the cracked weld is. I suspect this untorqued bolt allowed the system to move around way too much which stressed the weld.

Here's the kicker, while I was under the car with the mechanic, he denied that there was a crack...said that it was just how the weld looks It's obvious that there's a crack. At this point, I'm going to take it to another dealer because this one can't own up to the ****ty work that they performed.
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Old 08-18-2016, 04:48 PM
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Damn, always something with these crappy-ass cars. Well, I've had my entire ARS assembly replaced due to excessive leaks, so I guess anythings possible. Good luck...
I updated my findings after today. The loose bolt at the top of the support retaining bracket was allowing the entire assembly to flop around. As I mentioned, I'm fairly certain that excessive play stressed the weld and broke it. Of course the dealer denies that there's a crack present.
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Old 08-18-2016, 04:49 PM
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I hear a creaking sound in the front right above my head unit but it's not on turns tho mostly on speed bumps is this the same sound ?? Or it just my dashboard is old by the year of my car... :-/
Your issue sounds like it may be the strut tower brace bolts on the firewall.
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Old 08-18-2016, 05:43 PM
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Quote:
Originally Posted by TX550 View Post
The first time around, I honestly don't know what cracked it. There were not any impacts to the subframe itself. I'm currently at 150,000 miles. This time around, after talking with the dealer today and looking at the car on the lift with the tech, we found an extremely loose bolt on the top, driver side stabilizer support/retaining bracket. The loose bolt coincides with where the cracked weld is. I suspect this untorqued bolt allowed the system to move around way too much which stressed the weld.



Here's the kicker, while I was under the car with the mechanic, he denied that there was a crack...said that it was just how the weld looks It's obvious that there's a crack. At this point, I'm going to take it to another dealer because this one can't own up to the ****ty work that they performed.

Wow.

That is just messed up.

About a year ago, my Indy caught the loose strut tower brace bolts and tightened them and added Loctite. The loose bolts definitely made a creaking sound when turning or going over uneven surfaces.
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Old 08-18-2016, 06:08 PM
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Your issue sounds like it may be the strut tower brace bolts on the firewall.
if it is, how would i go take a look at it? exactly where is it, or its not easy to get to and would they only need to be tighten or replaced?


thanks again...
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Old 08-18-2016, 08:08 PM
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if it is, how would i go take a look at it? exactly where is it, or its not easy to get to and would they only need to be tighten or replaced?


thanks again...
Can't find an exact pic, but this is close enough. Look at the center of the firewall. Two bolts right next to each other. You'll need a Torx bit, the size escapes me...
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Old 08-18-2016, 08:38 PM
TX550 TX550 is offline
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Wow.

That is just messed up.

About a year ago, my Indy caught the loose strut tower brace bolts and tightened them and added Loctite. The loose bolts definitely made a creaking sound when turning or going over uneven surfaces.
I'm pretty livid with the dealership. The service director even went so far as to say that only the parts and not the work done to install the parts are warrantied
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Old 08-18-2016, 08:41 PM
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if it is, how would i go take a look at it? exactly where is it, or its not easy to get to and would they only need to be tighten or replaced?


thanks again...
The center bolts are under the cowl...beneath the cabin air filters. It's fairly straightforward to remove everything to access the bolts.
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Old 08-19-2016, 06:39 PM
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Well, the dealership didn't want to acknowledge their screw ups so I filed a complaint with BMW and the BBB. Meanwhile, I'm taking it to another dealership to have them verify the presence of a cracked weld.
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Old 08-19-2016, 07:19 PM
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Well, the dealership didn't want to acknowledge their screw ups so I filed a complaint with BMW and the BBB. Meanwhile, I'm taking it to another dealership to have them verify the presence of a cracked weld.

Hope it goes out well.
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Old 08-27-2016, 12:36 PM
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Update: the second dealership and I confirmed a crack. The weld holding the roll bar bracket to the subframe was completely cracked. The tech says it was most likely caused by the previous dealership not torquing the retaining bracket bolt to spec being that there was no evidence of an impact to the subframe. They were going to contact BMW and have them warranty the part. Hopefully BMW doesn't object and everything goes smoothly.

On a separate note, the dealer has me in an i3 loaner...it's a great little car!
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Old 08-27-2016, 06:37 PM
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Update: the second dealership and I confirmed a crack. The weld holding the roll bar bracket to the subframe was completely cracked. The tech says it was most likely caused by the previous dealership not torquing the retaining bracket bolt to spec being that there was no evidence of an impact to the subframe. They were going to contact BMW and have them warranty the part. Hopefully BMW doesn't object and everything goes smoothly.

On a separate note, the dealer has me in an i3 loaner...it's a great little car!

Let's hope that BMW covers the part.
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Old 08-31-2016, 06:37 PM
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Update 2: BMW accepted the warranty claim. The new subframe should be coming in tomorrow and the work should be done by Friday.

Lesson learned: I will not be taking my vehicle in for work at BMW of Corpus Christi ever again. They simply do not stand behind their work.
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Old 09-01-2016, 12:12 AM
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Update 2: BMW accepted the warranty claim. The new subframe should be coming in tomorrow and the work should be done by Friday.

Lesson learned: I will not be taking my vehicle in for work at BMW of Corpus Christi ever again. They simply do not stand behind their work.

Glad to hear that BMW is standing behind their work.
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Old 09-01-2016, 02:36 PM
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Had a similar problem, mine was out of warranty it the weld was broken.. I actually took it to a aluminum welder and he fixed that and reinforced the aluminum welds on both sides. I wondering I fit was caused by work done when they replaced my steering rack, not sure but car runs fine and the new welds look much sturdier than the factory ones... Glad you for it fixed.
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Old 09-01-2016, 11:02 PM
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Did you remove the subframe from the vehicle to have it welded or did the welder manage to do it with it still in place?
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Old 09-02-2016, 04:49 AM
thepresenceon2 thepresenceon2 is offline
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No, they managed to weld it with it on the vehicle.
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