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Discussion Starter · #1 ·
Like the title says, I'm preparing TAZ, my 520iA, for an aprox 5000km road trip. The Mrs aka The Dungeon Keeper planned our vacation, or better said, HER vacation in such a way that I'll be driving more than I'll be relaxing.
That being acknowledged I decided that brand new front bearings, brakes, polyurethane bushings, integral links, rear bushings and some miscellaneous bits and bobs like tailgate struts and wiper blades were to be fitted. Rest of the suspension was done 2 years ago( front+back complete suspension kits and new socks), oil change and a GB oil and filter change.
I went with *** for bearings, Ate for brake disks, brake fluid and caliper grease, Brembo for the pads and shoes, Lemfroder for the integral links and bushings, Powerflex for polyurethane bushings, Castrol GTX 5W-40 and a complete ZF transmission service kit.
The salty climate of Denmark is taking it's toll on the car even though it sits in the garage. Lots of the bolts were beginning to rust. Obviously headaches were expected and they didn't fail to appear. Patience and perseverance is the key... and reinventing the holy bible of romanian curses. In the end success was achieved.
A few pics.
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Discussion Starter · #2 ·
I started with the back, stuff came out pretty easy, went back in not so easy. But I managed.
The disk protection was repainted 3 years ago, not to much rust but I did them again. It was a nice touch.
Brake disks were so and so...but bad quality, so did the pads, the brake shoes had still life in them and looked decent. Rear bushings were 80% dead, integral link was perfect. Checked everything else and no issues were encountered.
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Discussion Starter · #3 ·
Moving to the front wheels, everything was changed 3 years ago when I imported the car from German, things held quite well but the quality of the brake disks and pads were to be questioned, due to the fact that they were replaced after a couple of months only, on warranty, because they ovalazied. A little shake when braking appeared, so ATE is the way to go.
Suspension components were checked and everything was fine. For sakes being Powerflex bushings were installed.
Disks dust cover was given a scrub with the wire brush and a fresh coat of paint. The most concerning was the whining of the bearings, they sounded like a pregnant wife in labor, they appeared to be the original ones. *** replacements were installed. Not without headaches. None of the videos or tutorials applied. My 18mm didn't fit because it was too bulky, smaller one cracked try to remove screws on the dreaded 530i, shocks were too long to pry down, ball joints were stuck and the press was too smallThe holly book of Romanian curses was consulted, spindle came out and job was done. First set of brake pictures is from 3 years ago, just for comparison means.
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'03 540, '03 M5
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No quit in you!
Nice work.

This weekend I bled the brakes, checked cooling system, and overall condition underneath the 540.
Changed an 02 sensor in the Tundra.
A slacker by comparison...

Safe cruising!
 

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Discussion Starter · #5 ·
The other side was copy/paste. With the same issues. Powerd through tough.
Brakes were bleed, I used Ate SL.6, Dot 4 special for cars with abs and esp, ( really low viscosity and recommended for the e39. )
Brakes feel so good.
Car feels so so stiff and so well put together. Polyurethane bushings really make a difference.
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Discussion Starter · #6 ·
No quit in you!
Nice work.

This weekend I bled the brakes, checked cooling system, and overall condition underneath the 540.
Changed an 02 sensor in the Tundra.
A slacker by comparison...

Safe cruising!
Thanks, I on my way to a " do it yourself workshop" how the call it here to do the transmission oil and filter change, engine oil change and refit all the shieldind under on a lift. I don't feel safe on the jacks and jack stands. This way is easier and more room. I did it the same last time.
I'll keep posting.


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Thanks, I on my way to a " do it yourself workshop" how the call it here to do the transmission oil and filter change, engine oil change and refit all the shieldind under on a lift. I don't feel safe on the jacks and jack stands. This way is easier and more room. I did it the same last time.
I'll keep posting.


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We also have a 'do it yourself' garage to rent a lift. Glad to hear you are not going underneath. I would not either. Nice of you to share your work on your car.
 

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'03 540, '03 M5
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I draw the line at AutoTrans service.
Just like paint, more ATF gets on me than where it was designated.

I was shocked to see a "Self service" garage here in SoCal.
We are in the most litigious state of the union.
That's saying something.
I just wish it was closer than 50 miles.
 

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‘89 325i, ‘98 528i, ‘99 528i, ‘03 325i
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You have an air compressor? My pressure bleeder had a bad hand pump on it so I removed the pressure gauge and threw on a regulator. Set it to 20psi, carry on with the whole car. It’s very convenient.

 

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Discussion Starter · #10 ·
20psi... be careful, you'll bubble up your fluid reservoir, mine showed stress marks at 12psi. It is very convenient, I also used to activate the abs pump, to loosen any possible trapped air bubbles. Mine feeds also fresh fluid. Wasn't even that expensive, 45€ ( 53$)

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My Motive pressure bleeder gauge has the green (safe region) up to 21 PSI.
Haven't has any issues at 20-21 in the past.
 

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I was flushing old fluid out of the e46 and the Bentley spec’s 2bar, I thought ~20 seemed safe. Not sure what the e39 Bentley says.
 

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For the E39 Bentley says 29 PSI, 2 bar max.
 

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Thanks Jim, I have the e39 Bentley, just wasn’t the last one I read so I wasn’t sure.
 

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I was surprised that the pressure was that high.
I’ve been using the Motive along with a vacuum bleeder at the calipers.
 

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Discussion Starter · #17 · (Edited)
Well.... the transmission oil change didn't go as planned....
Started with the engine oil, so the transmission can cool down a little, to be about 30°-40°C which is the recommended temp for oil change, and went very smooth, moved on to the rear O2 sensors, found one totally loose, everything was ok untill here.
Then the guy came and said the magic words ( 1h left until closing)
Ok.... should be enough. Moved on to the transmission, loosen up the plugs, started draining and it drained and drained it thought it will never stop... in the meantime I unscrewed the pan bolts, carefully, everything smooth, untill the LAST ONE, almost stripped it. With patience and sweats I got it out. Guy comes again( 30 min left) . Took the pan out, magnets were a bit smudged, very, very fine paste like on them, so more panic, I was not expecting anything because the oil change was done 3 years ago and then they were the same but after 19 years.
I replaced them, put the new gasket, put it up, 15min to go and I called it in. Had to push the car outside untill the next day after work. I didn't get to take more pictures

 

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Discussion Starter · #18 ·
Ista+ says the same thing, do not exceed 2 bar. I followed the procedure described there. Same info as in NewTIS
My reservoir started bubbling up and showed stress marks. My mistake, I also didn't release the pressure while moving in between wheels. First time bleeding with the bleeder.

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Tax, your pics aren’t showing. When I click on the View Attachment it comes up with an error message.
 
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