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How to change front suspension strut on BMW E60 – replacement guide

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Important!

This replacement procedure can be used for:
BMW 5 Saloon (E60) 525 d, BMW 5 Saloon (E60) 520 i, BMW 5 Saloon (E60) 530 i, BMW 5 Saloon (E60) 530 d, BMW 5 Saloon (E60) 525i, BMW 5 Saloon (E60) 545i, BMW 5 Saloon (E60) 535 d, BMW 5 Saloon (E60) 530i, BMW 5 Saloon (E60) 523 i, BMW 5 Saloon (E60) 525i, BMW 5 Saloon (E60) 540i, BMW 5 Saloon (E60) 550i, BMW 5 Saloon (E60) 520d, BMW 5 Saloon (E60) 530d, BMW 5 Saloon (E60) 525xi, BMW 5 Saloon (E60) 530 xi, BMW 5 Saloon (E60) 530 xd, BMW 5 Saloon (E60) 520d, BMW 5 Saloon (E60) 535 d, BMW 5 Saloon (E60) 525 i, BMW 5 Saloon (E60) 525xi, BMW 5 Saloon (E60) 523i, BMW 5 Saloon (E60) 525 d, BMW 5 Saloon (E60) 530 d, BMW 5 Saloon (E60) 530 xd, BMW 5 Saloon (E60) 530i, BMW 5 Saloon (E60) 530 xi, BMW 5 Saloon (E60) 530 i, BMW 5 Saloon (E60) 535i, BMW 5 Saloon (E60) 525xd, BMW 5 Saloon (E60) 520d, BMW 5 Saloon (E60) 520i, BMW 5 Saloon (E60) 520 i, BMW 5 Saloon (E60) 525 i xDrive, BMW 5 Saloon (E60) 530 d, BMW 5 Saloon (E60) 520i, BMW 5 Saloon (E60) 540i, BMW 5 Saloon (E60) 523i, BMW 5 Saloon (E60) 530i, BMW 5 Saloon (E60) 525 d … View more

The steps may slightly vary depending on the car design.

How to change a front shock strut on BMW E60 [TUTORIAL AUTODOC]

Alternative products

Shock absorber

Replacement: suspension strut – BMW E60. Tools you need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      Combination spanner #10
                    
                      Combination spanner #16
                    
                      Combination spanner #18
                    
                      Combination spanner #21
                    
                      Drive socket # 10 
                    
                      Drive socket # 13 
                    
                      Drive socket # 16 
                    
                      Drive socket # 18 
                    
                      Drive socket # 21 
                    
                      Drive socket # 22 
                    
                      Torx bit T30
                    
                      Torx bit T40
                    
                      HEX bit no.H6.
                    
                      HEX bit no.H7.
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Flat chisel
                    
                      Hammer
                    
                      Tap wrench
                    
                      Clip removal tool
                    
                      Phillips screwdriver
                    
                      Crow bar
                    
                      Ball joint puller
                    
                      Hydraulic strut spring compressor
                    
                      Hydraulic transmission jack
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: suspension strut – BMW E60. Tip from AUTODOC experts:

Both shock struts of the front suspension should be replaced simultaneously.
The replacement procedure is identical for the left and right shock struts of the front suspension.
All work should be done with the engine stopped.

Replacement: suspension strut – BMW E60. Take the following steps:

Step 1

Open the bonnet.
Step 2

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 3

Unscrew the fasteners of the suspension strut mount cover. Use a Phillips screwdriver. Use a clip removal tool.
Step 4

Remove the protective cap from the shock absorber strut mount.
Step 5

Clean the fasteners of the shock strut upper mount. Use a wire brush. Use WD-40 spray.
Step 6

Loosen the upper fastener of the shock strut mount. Use a drive socket #13. Use a ratchet wrench.
Step 7

Secure the wheels with chocks.
Step 8

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 9

Raise the front of the car and secure on supports.
Step 10

Unscrew the wheel bolts.

AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. BMW E60
Step 11

Remove the wheel.
Step 12

Disconnect the wiring and the brake hose from the bracket on the shock strut.
Step 13

Clean the fasteners of the headlight levelling sensor. Use a wire brush. Use WD-40 spray.
Step 14

Unscrew the fasteners of the headlight levelling sensor. Use a combination spanner #10.
Step 15

Disconnect the headlight levelling sensor.
Step 16

Clean the fasteners connecting the shock strut to the steering knuckle. Clean the stabiliser link fasteners. Use a wire brush. Use WD-40 spray.
Step 17

Unscrew the fastener connecting the stabilizer link to the shock strut. Use a combination spanner #16. Use Torx T30. Use a ratchet wrench.
Step 18

Remove the stabilizer rod.
Step 19

Unscrew the fastener of the stabiliser link bracket. Use a drive socket #16. Use a ratchet wrench.
Step 20

Unscrew the lower fastener connecting the shock strut to the steering knuckle. Use a combination spanner #18. Use a drive socket #18. Use a ratchet wrench.
Step 21

Clean the fastener connecting the tie rod end to the steering knuckle. Clean all joints of the arm. Use a wire brush. Use WD-40 spray.
Step 22

Unscrew the end fastening nut to the steering knuckle. Use a combination spanner #21. Use Torx T40. Use a ratchet wrench.
Step 23

Disconnect the tie rod end from the steering knuckle. Use a ball joint puller.
Step 24

Spread the brake pads. Use a crowbar.
Step 25

Unscrew the caliper bracket fastening. Use a drive socket #18. Use a tap wrench.
Step 26

Remove the brake caliper together with its bracket.

Replacement: suspension strut – BMW E60. AUTODOC recommends:
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur.
Step 27

Unscrew the rear fastener connecting the control arm to the subframe. Use a combination spanner #18. Use a drive socket #18. Use a ratchet wrench.
Step 28

Unscrew the front arm fastener. Use a combination spanner #18. Use a drive socket #18. Use a ratchet wrench.
Step 29

Disconnect the ABS sensor wiring.
Step 30

Prop up the steering knuckle. Use a hydraulic transmission jack.
Step 31

Remove the rear fastener of the control arm. Use a combination spanner #18.
Step 32

Remove the arm.
Step 33

Remove the front fastener of the control arm. Use a combination spanner #18.
Step 34

Remove the arm.
Step 35

Clean the fasteners connecting the shock strut to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 36

Remove the fastening bolt.
Step 37

Release the lower fastener connecting the shock strut to the steering knuckle. Use a flat metal-working chisel. Use a hammer.
Step 38

Lower the hydraulic transmission jack by 10-15 cm.

AUTODOC recommends:
BMW E60 – Do not lower the transmission jack sharply to avoid damaging components and mechanisms of the car.
Step 39

Disconnect the steering knuckle from the shock absorber strut.

Replacement: suspension strut – BMW E60. AUTODOC experts recommend:
Make sure that the steering knuckle is supported.
Step 40

Unscrew the top fastening of the shock strut mount.

Replacement: suspension strut – BMW E60. Tip:
To avoid injuries, hold the shock strut when undoing the fastening bolts.
Step 41

Remove the suspension strut.
Step 42

Set the shock absorber strut on the spring compressor tool.

Replacement: suspension strut – BMW E60. Tip from AUTODOC experts:
Note that when using a spring compressor, spring coils need to be securely gripped, compressing the spring on the opposite sides.Ensure the correct position of the spring in the retainer.Make sure that the spring coils tightly entered the lock handles.
Step 43

Compress the spring.
Step 44

Remove the shock strut mount cap. Use a crowbar.
Step 45

Treat the shock strut rod. Use a wire brush. Use WD-40 spray.
Step 46

Remove the strut piston rod nut. Use a drive socket #21. Use HEX No.H7. Use a ratchet wrench.
Step 47

Remove the top strut mount.
Step 48

Release the coil spring.
Step 49

Remove the spring.
Step 50

Remove the shock absorber dust cap and the bump stop.

AUTODOC recommends:
Replacement: suspension strut – BMW E60. Carefully inspect the mount, the boot, and the bump stop of the shock absorber. Replace if necessary.
Step 51

Remove the old shock absorber from the hydraulic coil spring compressor.

Replacement: suspension strut – BMW E60. Tip from AUTODOC:
Before installing a new shock absorber you should pump it manually 3-5 times.
Step 52

Install the new shock absorber on the hydraulic coil spring compressor.
Step 53

Install the dust sleeve and the bump stop on the new shock absorber.
Step 54

Install the spring on the shock absorber.
Step 55

Compress the spring.
Step 56

Install the upper strut mount and the strut mount bearing.
Step 57

Tighten the shock strut piston rod nut. Use a drive socket #22. Use HEX No.H6. Use a torque wrench. Tighten it to 64 Nm torque.

Replacement: suspension strut – BMW E60. AUTODOC recommends:
Check to make sure the spring is positioned correctly. Avoid its misalignment.
Step 58

Treat the shock strut rod. Use copper grease.
Step 59

Install the shock strut mount cap.
Step 60

Decompress the spring.
Step 61

Remove the assembled shock strut.
Step 62

Treat the shock strut mounting seat on the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 63

Install the shock strut into the wheel arch.
Step 64

Screw the top fastening of the shock strut mount. Do not tighten it.

Replacement: suspension strut – BMW E60. AUTODOC experts recommend:
To avoid injuries, hold the shock strut when screwing the fastening bolts in.
Step 65

Treat the shock strut mounting seat on the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 66

Fix the shock absorber strut on the steering knuckle.
Step 67

Install the fastening bolt.
Step 68

Screw in the fastener of the stabiliser link bracket. Use a drive socket #16. Use a ratchet wrench.
Step 69

Screw in the fastener that connects the shock strut to the steering knuckle. Use a drive socket #18. Use a ratchet wrench.
Step 70

Clean the mounting seats and the thread of the suspension arm. Use a wire brush. Use WD-40 spray.
Step 71

Reinstall the control arm.
Step 72

Install the front fastener of the arm.
Step 73

Screw the front arm fastener. Use a combination spanner #18. Use a drive socket #18. Use a ratchet wrench.
Step 74

Reinstall the control arm.
Step 75

Install the rear fastener of the arm.
Step 76

Screw the rear fastener connecting the control arm to the subframe. Use a combination spanner #18 (2 pieces).
Step 77

Remove the support from under the steering knuckle.

AUTODOC recommends:
Replacement: suspension strut – BMW E60. Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 78

Clean the mounting seats of the tie rod end. Use a wire brush. Use WD-40 spray.
Step 79

Connect the tie rod end to the steering knuckle.
Step 80

Screw on the fastening nut that connects the tie rod end to the steering knuckle. Use a combination spanner #21. Use Torx T40. Use a ratchet wrench.
Step 81

Clean the mounting seats of the stabiliser link. Use a wire brush. Use WD-40 spray.
Step 82

Ιnstall the transverse stabilizer link.
Step 83

Tighten the stabiliser link fastener. Use a combination spanner #16. Use Torx T30. Use a ratchet wrench.
Step 84

Connect the ABS sensor wiring.
Step 85

Reconnect the headlight levelling sensor.
Step 86

Screw in the fasteners of the headlight levelling sensor. Use a combination spanner #10.
Step 87

Clean the mounting seats of the caliper and its bracket. Use a wire brush. Use WD-40 spray.
Step 88

Install the brake caliper together with its bracket.
Step 89

Tighten the brake caliper bracket. Use a drive socket #18. Use a torque wrench. Tighten it to 110 Nm torque.
Step 90

Fasten the brake hose on the strut.
Step 91

Tighten the fasteners of the headlight levelling sensor. Use a drive socket #10. Use a torque wrench. Tighten it to 7 Nm torque.
Step 92

Tighten the fastener connecting the stabilizer link to the shock strut. Use a drive socket #16. Use a torque wrench. Tighten it to 65 Nm torque.
Step 93

Tighten the fastening nut connecting the tie rod end to the steering knuckle. Use a drive socket #21. Use a torque wrench. Tighten it to 165 nm torque.
Step 94

Tighten the lower fasteners connecting the shock strut to the steering knuckle. Use a drive socket #18. Use a torque wrench. Tighten it to 81 Nm torque.
Step 95

Tighten the fastener of the stabiliser link bracket. Use a drive socket #16. Use a torque wrench. Tighten it to 65 Nm torque.
Step 96

Prop up the steering knuckle. Use a hydraulic transmission jack.
Step 97

Tighten the front fastener connecting the control arm to the subframe. Use a combination spanner #18. Use a drive socket #18. Use a torque wrench. Tighten it to 100 Nm torque.+90°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 98

Tighten the rear fastener connecting the arm to the body subframe. Use a combination spanner #18. Use a drive socket #18. Use a torque wrench. Tighten it to 100 Nm torque.+90°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 99

Remove the support from under the steering knuckle.

Replacement: suspension strut – BMW E60. Professionals recommend:
Lower the hydraulic transmission jack smoothly, without jerks, to avoid damaging assemblies and mechanisms.
Step 100

Treat all joints of the arm. Treat the shock strut fasteners. Use copper grease.
Step 101

Clean the wheel rim mounting seat. Use a wire brush.
Step 102

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 103

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: suspension strut – BMW E60. After applying the spray, wait a few minutes.
Step 104

Install the wheel.

Replacement: suspension strut – BMW E60. AUTODOC recommends:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 105

Screw in the wheel bolts. Use wheel impact socket #17.
Step 106

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #17. Use a torque wrench. Tighten it to 120 Nm torque.
Step 107

Remove the jacks and chocks.
Step 108

Tighten the upper fastener of the shock absorber strut mount. Use a drive socket #13. Use a torque wrench. Tighten it to 34 Nm torque.
Step 109

Treat the fasteners of the shock strut mount. Use copper grease.
Step 110

Install the protective cap onto the shock absorber strut mount.
Step 111

Screw in the fasteners of the suspension strut mount cover. Use a Phillips screwdriver.
Step 112

Remove the fender protection cover.
Step 113

Close the hood.

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