How to change rear brake discs on BMW E39 – replacement guide
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Recommended replacement interval for the part category Brake disc : 50000km
Important!
This replacement procedure can be used for:
BMW 5 Saloon (E39) 520 i,
BMW 5 Saloon (E39) 520 i,
BMW 5 Saloon (E39) 520 d,
BMW 5 Saloon (E39) 525 td,
BMW 5 Saloon (E39) 523 i,
BMW 5 Saloon (E39) 525 tds,
BMW 5 Saloon (E39) 520 i
…
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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]
All the parts you need to replace – Brake Discs for 5 Saloon (E39) and other BMW models
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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