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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 08-28-2019, 12:11 PM
plus1111 plus1111 is offline
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Rear Brake Lines - 2006 E61

Has anyone replaced their rear brake lines? Mine popped yesterday. It looks like they run inside the quarter panel under the doors on the drivers side bit I am not quite sure how to remove the panel.
I popped the row of bottom fasteners and a bolt at each end but it's still on tight.
The Bentley doesn't show me and I'd rather have suggestions before I pry hard enough to snap something.
Thanks!
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  #2  
Old 08-28-2019, 07:51 PM
dharmabmw dharmabmw is offline
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Been there, done that. Ugly job for sure. The process involves removing the rear under panels including the under fender liners. Left and right are parallel for a ways until the axel. There's a coupling just ahead of the left rear tire. I replaced both left and right at the same time with custom bent cuni tubing, since the cause of the failure in my case was rust through at a spot just ahead of the left rear tire die to sand and salt accumulation. Have a look at my post on the process.
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  #3  
Old 08-28-2019, 07:57 PM
plus1111 plus1111 is offline
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Thanks for the speedy reply. I studied it more after I asked my question and guessed I'd have to pull the fender liners. This is not my first brake line replacement but all the others were older American cars with plenty of room for new lines. I'll go study your into now.
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #4  
Old 08-31-2019, 05:05 PM
audiophool audiophool is offline
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I need to check mine. Just did this on an E53. Lines rusty under the driver's seat area. Made up lines myself using new fittings. I used M10x1 in all places as the M12x1 couplers were a lot more money and I'm unlikely to mix up lines when I'm doing them one at a time.

I had the rear fender liners out recently to do rear shocks (hard to do without taking out the liners). Not a hard job getting the liners out.
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  #5  
Old 08-31-2019, 07:08 PM
plus1111 plus1111 is offline
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The only part that worries me is where the lines cross from the left side of the car to the right behind the engine. Not sure how to get in there. I may run the new lines down the right side of the body. My new nickel copper stuff arrives tomorrow.
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #6  
Old 08-31-2019, 07:50 PM
dharmabmw dharmabmw is offline
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Quote:
Originally Posted by plus1111 View Post
The only part that worries me is where the lines cross from the left side of the car to the right behind the engine. Not sure how to get in there. I may run the new lines down the right side of the body. My new nickel copper stuff arrives tomorrow.
You should follow the existing path. The brake line mounts already exist so why would you want to drill holes where none exist?
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  #7  
Old 09-01-2019, 06:46 AM
plus1111 plus1111 is offline
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I prefer to follow the existing lines. Just haven't figured out how to go behind the engine. I guess I'' go explore more. The Bentley manual has zero info for this - grr.
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #8  
Old 09-01-2019, 08:56 AM
audiophool audiophool is offline
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I'd be surprised if the ones running behind the engine would need changing. If there's a portion that's rusty and exposed, it can be spliced using an ISO bubble flare tool. Here's a picture of what I did on the X5. This line was rusty on both sides of the splice and I didn't want to go all the way to the DSC pump.
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Last edited by audiophool; 09-01-2019 at 08:58 AM.
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  #9  
Old 09-01-2019, 09:13 AM
plus1111 plus1111 is offline
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Heyy... that might work. I was planning to run a single line to the pump just because. There probably is no good reason for me to do that tho. I'll look. Me roll of tubing just arrived. Thanks!
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #10  
Old 09-01-2019, 09:21 AM
audiophool audiophool is offline
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A word of advice if you're going to splice: practice with the bubble flare tool using pieces of the new tubing before you try it on a stub on the body. I used a practice piece to make a line plug (you can see it in the pic with the FU gloves). Cut the body line, put the new fitting on the line, flare it, then plug with a coupler and the practice piece. This will stop fluid leaking out too much - draining the master cylinder will give you fits whilst trying to bleed the lines.
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  #11  
Old 09-01-2019, 09:34 AM
plus1111 plus1111 is offline
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Thanks for the tip. I've been replacing brake line for decades bit this system is quite a bit different. I do have a pressure bleeder which should help some.
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #12  
Old 09-01-2019, 12:32 PM
audiophool audiophool is offline
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Quote:
Originally Posted by plus1111 View Post
Heyy... that might work. I was planning to run a single line to the pump just because. There probably is no good reason for me to do that tho. I'll look. Me roll of tubing just arrived. Thanks!
A single line would have defeated your ABS/DSC too.

I have a Motive pressure bleeder and used it on the X5 but still had a soft pedal until I combined it with ABS pump using my scan tool.
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  #13  
Old 09-01-2019, 07:31 PM
plus1111 plus1111 is offline
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I was unclear. I was going to run a single piece or tubing for each side from the front to back without unions. Your idea is better and the lines behind the engine look fine.
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We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #14  
Old 09-01-2019, 09:14 PM
audiophool audiophool is offline
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That makes more sense now you spell it out.
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  #15  
Old 09-07-2019, 07:05 PM
plus1111 plus1111 is offline
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I finally got the needed supplies and found the tools I will need (organization is not my strength.) I found the lines that come down from the engine compartment to the rear have unions just behind the front wheel. The look great forward to the engine compartment. This just simplified things greatly. Tomorrow I should have a car that stops again!
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Hobby mechanic doing my own work for 50 years or so.
We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #16  
Old 09-07-2019, 09:28 PM
dharmabmw dharmabmw is offline
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I used a spread sheet to quantify the lengths and bends required to fabricate the new lines as I needed to cut the lines in two pieces to facilitate the removal. I will try to dig it up and post it of I still have it. I needed some help with installation of the new lines because there is a ninety degree bend in each of them that cannot be done before hand.
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  #17  
Old 09-07-2019, 10:32 PM
plus1111 plus1111 is offline
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I bought copper/nickle line this time. It is suppose to resist rust and decomposition. It's also suppose to be easy to bend, even by hand. We will see tomorrow.
__________________
Hobby mechanic doing my own work for 50 years or so.
We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #18  
Old 09-08-2019, 06:30 AM
dharmabmw dharmabmw is offline
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Originally Posted by plus1111 View Post
I bought copper/nickle line this time. It is suppose to resist rust and decomposition. It's also suppose to be easy to bend, even by hand. We will see tomorrow.
It's easier to bend than steel but you should still use tools. It's easier to kink the tubing. Additionally, copper gets brittle the more you work it, so try and do the bends correctly the first time.
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  #19  
Old 09-08-2019, 08:26 AM
plus1111 plus1111 is offline
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Thanks for the tip. I intend to use bending tools, I've kinked too many over the years.
__________________
Hobby mechanic doing my own work for 50 years or so.
We have a 2006 530xi Touring and a 2008 535xi sedan.
I can't really remember the last time I took a car to a repair service.
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  #20  
Old 09-08-2019, 10:50 AM
audiophool audiophool is offline
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The bender and the flare tool set me back less than C$80. Cheap enough to make buying a 'no brainer'.
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