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Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E60 / E61 (2004 - 2010)

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 06-24-2016, 01:41 AM
rkilpa rkilpa is offline
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Location: Victorville, CA
 
Join Date: Oct 2013
Posts: 112
Mein Auto: '09 550i / '05 330ci ZHP
Thigh support adjuster repair $40 SOLUTION

There are a lot of threads about the thigh support adjuster not working on the E60. In the various threads it is concluded that the plastic gear within the motor housing of the adjuster breaks from age or impact.

Both of my thigh supports didn't work. I found that I was always pushing the broken thigh support back into the seat after I exited my car. I believe that shifting your weight forward on the thigh support when you exit the car applies excessive force on the gear and is probably what causes the plastic gear to eventually snap.

I didn't really even use the thigh support, but I was tired of pushing the support back into the seat every time I exited the car. The solutions I found in the various threads were:

1) spend almost $400 for 2 new factory replacement assemblies with the same plastic gear that will break again. (very expensive and will break again)

2) try to glue the broken plastic gear halves back together (doesn't work)

3) purchase an $81 gear on eBay from Taiwan that needs to be pounded onto the existing worm gear ($162 for 2 little pieces of metal?)

I have not seen the following solution presented yet, so I thought I would share my experience and recommendation:

https://vanos-bmw.com/gear-repair-se...45-52100309476

The best repair method consists of a solid brass one-piece gear and worm replacement from this company located in Russia. The part is available directly from their website, but they also have a listing on eBay. I purchased 2 from eBay and received the parts in a little over a week.

I found this part because I was looking on eBay at that $81 gear again, and I noticed the price had been reduced to $51. I almost went that direction. However, when I entered BMW part #52107068045 to see what the assembly was selling for, this part came up.

There were a couple of choices from China for less money, but the Russian part is solid brass and so is the gear on the motor. For a few dollars more, I didn't want to chance a different metal damaging the motor gear.

I just installed them tonight and they both fit and work perfectly. For less than $100 I have 2 working thigh supports that should hold up for a very long time.
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  #2  
Old 06-24-2016, 05:10 AM
etnav382 etnav382 is offline
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Location: Birmingham, AL
 
Join Date: Oct 2010
Posts: 667
Mein Auto: 06 550i
This is a great quality post!

Mine still work but i might just do some PM on the gear.

Thanks a lot!
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  #3  
Old 06-24-2016, 05:10 AM
etnav382 etnav382 is offline
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Location: Birmingham, AL
 
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Posts: 667
Mein Auto: 06 550i
Double post.
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  #4  
Old 06-24-2016, 06:12 AM
Kurt_ Kurt_ is offline
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Location: Ontario
 
Join Date: Nov 2014
Posts: 915
Mein Auto: 2007 530xi
Should see if we can get a bulk discount going on. I managed to glue mine back together, but I wouldn't be opposed to a permanent fix.
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