Recommended replacement interval for the part category Brake disc : 50000 km

Important!

This replacement procedure can be used for:
BMW 5 Saloon (E39) 520i, BMW 5 Saloon (E39) 525tds, BMW 5 Saloon (E39) 523i, BMW 5 Saloon (E39) 525 td, BMW 5 Saloon (E39) 520 d, BMW 5 Saloon (E39) 520 i, BMW 5 Saloon (E39) 520 i … View more

The steps may slightly vary depending on the car design.

How to change rear brake discs / rear brake rotors on BMW 520i (E39) [TUTORIAL AUTODOC]

Alternative products

Brake disc

Replacement: brake discs – BMW E39. Tools you'll need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      Combination spanner #16
                    
                      HEX bit no.H6.
                    
                      HEX bit no.H7.
                    
                      Drive socket # 16 
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Brake caliper wind back tool
                    
                      Impact screwdriver
                    
                      Crow bar
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: brake discs – BMW E39. AUTODOC recommends:

Replace the brake disks on the car BMW E39 in complete set for each axis. Regardless of the state of components. This will ensure even braking.
The replacement procedure is identical for both brake disks on the same axle.
When changing the brake discs, always replace the brake pads.
Please note: all work on the car – BMW E39 – should be done with the engine switched off.

Carry out replacement in the following order:

Step 1

Open the bonnet.
Step 2

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

Step 3

Detach the air duct from the cabin filter housing.
Step 4

Release the cabin filter cover clips.
Step 5

Remove the cabin filter housing cover.
Step 6

Remove the cabin filter housing seal.
Step 7

Remove the cabin air filter housing.
Step 8

Unscrew the brake fluid reservoir cap.
Step 9

Secure the wheels with chocks.
Step 10

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 11

Raise the rear of the car and secure on supports.
Step 12

Unscrew the wheel bolts.

AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. BMW E39
Step 13

Remove the wheel.
Step 14

Disconnect the brake pads wear sensor. Use a crowbar.

Please note!
Some cars are not equipped with the brake pad wear sensor.
Step 15

Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
Step 16

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 17

Spread the brake pads. Use a crowbar.
Step 18

Detach the brake caliper retaining spring. Use a crowbar.
Step 19

Remove the brake caliper.

Replacement: brake discs – BMW E39. Professionals recommend:
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. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
Step 20

Remove the brake pads.
Step 21

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 22

Unscrew the caliper bracket fastening. Use a combination spanner #16.
Step 23

Remove the caliper bracket.
Step 24

Clean the brake disc fasteners. Use a wire brush. Use WD-40 spray.
Step 25

Unscrew the brake disc fastening. Use HEX No.H6. Use an impact screwdriver.
Step 26

Remove the brake disc.
Step 27

Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 28

Install the brake disc.
Step 29

Tighten the brake disc fastening. Use HEX No.H6. Use a torque wrench. Tighten it to 16 Nm torque.
Step 30

Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.

AUTODOC recommends:
After applying the spray, wait a few minutes.
Step 31

Install the brake caliper bracket.
Step 32

Tighten the brake caliper bracket. Use a drive socket #16. Use a torque wrench. Tighten it to 65 Nm torque.
Step 33

Treat the brake caliper piston. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – BMW E39. After applying the spray, wait a few minutes.
Step 34

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 35

Install the brake pads.
Step 36

Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 30 Nm torque.
Step 37

Install the dust boot caps of the brake caliper guide pins.
Step 38

Connect the brake pads wear sensor.
Step 39

Install the brake caliper retaining spring.
Step 40

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 41

Clean the brake disk surface. Use a brake cleaner.

Replacement: brake discs – BMW E39. AUTODOC experts recommend:
After applying the spray, wait a few minutes.
Step 42

Install the wheel.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while screwing in the fastening bolts on the car. BMW E39
Step 43

Screw in the wheel bolts. Use wheel impact socket #17.
Step 44

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.

AUTODOC recommends:
Important! Replacement: brake discs – BMW E39. Check the brake fluid level in the reservoir and top up if necessary.
Step 45

Tighten the brake fluid reservoir cap.

Replacement: brake discs – BMW E39. AUTODOC recommends:
Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 46

Install the cabin air filter housing.
Step 47

Reinstall the cabin filter housing seal.
Step 48

Reinstall the cabin filter housing cover. Make sure you hear a click indicating that it is locked in place.
Step 49

Attach the cabin filter cover clips.
Step 50

Install the air duct housing.
Step 51

Remove the fender protection cover.

Step 52

Close the hood.
Step 53

Remove the jacks and chocks.

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