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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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  #101  
Old 10-07-2018, 08:46 PM
H F H F is offline
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Originally Posted by oldiegoodie View Post
I have this thread stored as a separate link for my future build! This is great stuff H F !!! Thanks for sharing all the little bits of information along with pictures.
Glad you can utilize the information , have lots more to post . That's what this site is all about .
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  #102  
Old 10-07-2018, 08:58 PM
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Oh yeah... Your gonna be so happy dude, i cant wait for you to come back and put that review down..

I guess we get to find out soon if im really crazy or not..
Think you're right ,,I'm already pretty stoked and not done yet ... Comparing the power flex to the original , there is a difference between the two . I'll elaborate on this more with a new set of pictures of my progress .

Never thought you were crazy man , I just wasn't convinced .. As far as the front,, I'm still really not convinced , compared to the mono ball .

But the front stock control thrust arm bushing ,,I do think the power flex is better .. As long as that bushing doesn't start the dolphin mating calls . Lol

For the rear swing arm and the rear control arm I am convinced it's much better . That bushing is way better than stock ,,now that I have it on hand , and installed on right rear , comparing the two ..

So I will say , you are right about that ...
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  #103  
Old 10-08-2018, 03:31 AM
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Under the lift arms
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when those mono balls fail.. replace them with powerflex.. and never have to work on your suspension again (its nice going 100k on alignment)

set of tires after set of tires they come off evenly worn.. you put more on and keep rolling

you might get dolphining on the front when you turn the wheel when your at a light or stopped or something *when its wet out

But you cant hear that out side the car, it just travels up the steering coloum
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  #104  
Old 10-08-2018, 01:20 PM
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Control arm and guide arm stock bushings are out . Power flex bushings are pressed in ,ready for installation .
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  #105  
Old 10-08-2018, 01:40 PM
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Here are the comparisons , swing arm , control and guide arm bushings ,, stock Vs power flex .

First pic , its clear ,, that the stock rubber busing is smaller than power Flex . Thus having more flexibility and less rigidity ... Power flex has more mass on the entire length of the sleeve . Thus increasing rigidity and less flexibility ..

Second pic ,, same thing ,, power flex has a larger mass thru the entire sleeve length , and will have less give ..

4th and 5th the control arm bushing is way way more stout with the sleeve and larger bushing mass .. Its superiority is very clear ..
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  #106  
Old 10-08-2018, 06:07 PM
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Swing arm is back in . Using a tie down strap to hold the axle shaft up and out of the way , came in really handy .
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  #107  
Old 10-08-2018, 06:24 PM
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Swing arm ball joint pressed in , integral link and guide arm installed .
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  #108  
Old 10-08-2018, 10:00 PM
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Removing necessary parts off the old struts and preparing the coil overs for installation.
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  #109  
Old 10-08-2018, 10:33 PM
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So all new parts are installed , everything is hand snug . Will torque down the coil over , ball joints on the control arm ,guide arm and swing arm ball joint . Will torque down the bushings on the swing arm , control and guide arms once I load the suspension ..

Sorry guys ,, don't understand why some pics are sideways they are vertical on my phone .

Next I'll start disassembly on the driver rear .
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  #110  
Old 10-09-2018, 01:04 AM
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Under the lift arms
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its race car time
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  #111  
Old 10-09-2018, 09:25 AM
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its race car time
Getting close , but I have to pull off for a little . Daughters Santa Fe is not starting ,so I have to sort that out . And FCP sent me two right side control arms . So I have to return and wait for the correct one to arrive . Still waiting for the rebound extensions for the front coil overs . so I pulled off the fronts , and they are half done . So I have delays on three corners ,, And can't get them wrapped up ...
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  #112  
Old 10-09-2018, 02:32 PM
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that is going to be a very stiff,, very aggressive, LONG lasting suspension

you went crazier then me on this one.. you went total race car : I am impressed
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  #113  
Old 10-09-2018, 03:11 PM
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This is great and I want it all. I can't believe how much beefier those bushings are.

Life happens. Whatever you post up next will be worth the wait. I'm loving how well documented everything is. I'll be referring to this in the future.
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  #114  
Old 10-09-2018, 03:12 PM
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all i can do is hope Hf likes it and he lets someone else drive it..

its going to be a completely different animal
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  #115  
Old 10-13-2018, 07:58 PM
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that is going to be a very stiff,, very aggressive, LONG lasting suspension

you went crazier then me on this one.. you went total race car : I am impressed
Thanks man , your input had a big part in my decision to go for the power flex in the rear . .. That's exactly what I want . Nice and stiff ,, with more rigidity and less give . When I said I'm all in , I meant it . And I expect it to be very aggressive . This thing was a cornering machine bone stock ,,, now it's going to be the Ultimate 4 door cornering machine ...

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Originally Posted by Burning2nd View Post
all i can do is hope Hf likes it and he lets someone else drive it..

its going to be a completely different animal
I'm for sure going to like it .. Not too crazy about letting people drive my baby , not many people have driven my car .
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  #116  
Old 10-13-2018, 08:12 PM
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This is great and I want it all. I can't believe how much beefier those bushings are.

Life happens. Whatever you post up next will be worth the wait. I'm loving how well documented everything is. I'll be referring to this in the future.
Ya , when I compared them side by side , thought , this is a no brainer . I didn't really like the stock rear control arm bushing is what really made it easy to pull the trigger . Plus burnings persistance in convincing me . When I looked at the picture on Powe Flex web site , I was like that is one stout looking set up . I just had to have it to balance out front and rear for hard cornering ,, interms of flexibility and rigidity ..

I'm finally back to it , finished working on three cars , changed the starter and oil pan gaskst on my daughters Hyundai Santa Fe . Installed a alternator on my buddies Chevy van , and changed the spark plugs and fixed the headlights on the Colorado.

So I'm back on the 545 tomorrow, more pics coming soon ..
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  #117  
Old 10-14-2018, 12:50 AM
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its going to be on rails.. with out any exaggeration

your diffidently going to have to tweak the struts though, its going to be so much stiffer.. that it might under steer or over steer (depending on how you left them)

if you make the struts soft, it should under steer if you make them to stiff it should over steer

Id start with making the both the same in the neutral position (3 of 6 or 5 of 10 how ever your damper rate is ) Then you will probably end up with the rear being slightly higher damper rate then the front Unless you want under steer... personal preference of racing i guess
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  #118  
Old 10-14-2018, 01:09 PM
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its going to be on rails.. with out any exaggeration

your diffidently going to have to tweak the struts though, its going to be so much stiffer.. that it might under steer or over steer (depending on how you left them)

if you make the struts soft, it should under steer if you make them to stiff it should over steer

Id start with making the both the same in the neutral position (3 of 6 or 5 of 10 how ever your damper rate is ) Then you will probably end up with the rear being slightly higher damper rate then the front Unless you want under steer... personal preference of racing i guess
Definitely going to play with the adjustments. And yes ,, I was thinking the same thing , adjusting them at the happy medium point right in the middle ,and see how she handles .

I have plenty of adjustment settings ,, 16 click compression and 20 clicks on rebound . I want to be able to keep the front end from dropping hitting the breaks into the turns . Same thing on the rear as I accelerate out keeping the car level breaking and gasing out . While Keeping under and over steer in control . Personally I'd rather have a little more over steer than under steer . So it will be fun going thru the settings to find the right combinations....
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  #119  
Old 10-14-2018, 02:37 PM
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What i did was start 50/50 and then i brought the rear down a little... and then the front up a little.. and then the rear back up..

which would have been just bringing the front up a little At the start..

BUT you have time to feel it out and learn to redrive that unit, shes gonna a different machine

next is gonna be rotors and ss lines lol
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  #120  
Old 10-14-2018, 08:41 PM
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What i did was start 50/50 and then i brought the rear down a little... and then the front up a little.. and then the rear back up..

which would have been just bringing the front up a little At the start..


BUT you have time to feel it out and learn to redrive that unit, shes gonna a different machine

next is gonna be rotors and ss lines lol
Wait ,, are we talking the same thing here ?? Are you talking ride height ?
I'm talking front end compression during hard braking ,, and rear end compression on acceleration ..

Yes , definitely ,, she is going to be like some new strange .


I already have SS lines . Want the M5 calipers and rotors , but that's going to require new wheels and tires . I would rather throw the cash towards a Quaife or M Factory LSD .
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  #121  
Old 10-15-2018, 01:13 AM
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Wait ,, are we talking the same thing here ?? Are you talking ride height ?
.
nope the bound and rebound rate is what your gonna work with.. after you get it set to the height you want

adjusting the height will result in you needing another alignment

get it to what you want, get it aligned and then mess with the bound and rebound rate
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  #122  
Old 10-15-2018, 09:35 AM
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nope the bound and rebound rate is what your gonna work with.. after you get it set to the height you want

adjusting the height will result in you needing another alignment

get it to what you want, get it aligned and then mess with the bound and rebound rate
Ya , just wanted to make sure we were on the same page compression and rebound adjustment .. I was already thinking passed ride height and alignment... which I'm going to keep it at factory low slung ride height .. Don't want to go any lower than that .
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  #123  
Old 10-16-2018, 01:20 AM
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the factory height on these cars is already pretty low, back when i use to actually drive lowered cars.. (pulling in to parken lots sideways and ****) I got use to "save the nose" mentality

when i said good bye to lowered honda stance, I had a hard time for a long long time just pulling in normal.. *i was use to it

you shouldn't have to go much lower.. after the alignment is set your damper rate adjustment is just a few clicks.. I found that a little stiffer in the rear gives the ass end a nice hugging feeling when your in the turn underpower,

You will be most impressed.. and im whilling to bet your probably a polyurethane bushing head for life now, youll start to want to replace bushings on other stuff with polyurethane. minus the struts what was the total number on the e60 for the set?

Im working my way thru now, im also acquiring parts for future projects, i have half of the suspension on hand, some of the bushings I already had (but im in the middle of doing a 125g saltwater reef tank that my wife insists i finish now that the new floor is done)

so for the car its pretty much if its not broken im not allowed to fix it lol
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  #124  
Old 10-17-2018, 09:25 AM
H F H F is offline
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Originally Posted by Burning2nd View Post
the factory height on these cars is already pretty low, back when i use to actually drive lowered cars.. (pulling in to parken lots sideways and ****) I got use to "save the nose" mentality

when i said good bye to lowered honda stance, I had a hard time for a long long time just pulling in normal.. *i was use to it

you shouldn't have to go much lower.. after the alignment is set your damper rate adjustment is just a few clicks.. I found that a little stiffer in the rear gives the ass end a nice hugging feeling when your in the turn underpower,

You will be most impressed.. and im whilling to bet your probably a polyurethane bushing head for life now, youll start to want to replace bushings on other stuff with polyurethane. minus the struts what was the total number on the e60 for the set?

Im working my way thru now, im also acquiring parts for future projects, i have half of the suspension on hand, some of the bushings I already had (but im in the middle of doing a 125g saltwater reef tank that my wife insists i finish now that the new floor is done)

so for the car its pretty much if its not broken im not allowed to fix it lol
That makes a lot of sense to me because the rear end does swing back n forth in the snakes.
So stiffer in the rear is a great suggestion . I will take you up on that and set it up that way .

Those poly bushings are much heavier duty than the stock bushings . And very noticeable when in a side by side comparison. Especially the rear control arm . Pictures of the bushings don't do them justice . You pretty much have to have them in hand to see it ..

Well ,. I'm going ahead and getting the ARS bushings too. So ,,I reckon,, I maybe a poly head now .. lol

Haven't added up the total cost yet , actually I'm afraid to see how much I've spent .

Off the top of my head the poly bushing were around 300+ , front end parts 600+, rear parts 300+. Plus all the misc nuts and bolts . Im around at least $1500.00 .. Plus the V3's and monoballs .

And I really don't care that I've dropped all this cash on my ride . People Will say it's just as much as the blue book value .. ok , but what will you get for 4000 bucks . Not a car in a condition as mine , that is solid and reliable , well taken care of that's going to have Porsche like handling. And I know, for a fact ,that I can give them a run for their money In The twisties ... and that's before all these upgrades .

Handling is a big deal for me and in my opinion it's money well spent on something that makes a huge difference . Compared to spending money on fancy wheels and Mtec bumpers , that do nothing for performance or handling only looks .... But that's just my opinion...
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  #125  
Old 10-17-2018, 09:36 AM
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Mein Auto: e39, e83, e60
well congratulations, you have the best handling e60 in the section lol

chasing corvettes and 911's is a reality now
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