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Front Axle - Repair BMW M5 E60/E61

Axle Shafts 58 illustrations ~4915 words

00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN

Danger of poisoning!

Ingesting oil or absorbing through the skin may cause poisoning!

Possible symptoms are

  1. Headaches
  2. Dizziness
  3. Stomach aches
  4. Vomiting
  5. Diarrhoea
  6. Cramps/fits
  7. Unconsciousness

Protective measures/rules of conduct

  1. Pour oil only into appropriately marked containers
  2. Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
  3. Observe country-specific safety regulations

First aid measures

  1. Do not induce vomiting. If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and consult a doctor immediately. If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery position and seek immediate medical attention.

00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN

Danger of injury!

Contact with eyes or skin may result in injury!

Possible symptoms are

  1. Impaired sight
  2. Irritation of the eyes
  3. Reddening of the skin
  4. Rough and cracked skin

Protective measures/rules of conduct

  1. Wear protective goggles
  2. Wear oil-resistant protective gloves
  3. Observe country-specific safety regulations

First aid measures

  1. Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-rinsing bottle. If irritation of the eyes persists, consult a doctor.
  2. Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor. NOTE: Do not use solvents/thinners.

00 SAFETY INSTRUCTIONS FOR HANDLING OIL

WARNINGDanger of poisoning if oil is ingested/absorbed through the skin! Risk of injury if oil comes into contact with eyes and skin!

Recycling

Observe country-specific waste-disposal regulations.

Measures if oil is unintentionally released

  1. Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work area. Wear personal protective clothing/equipment.
  2. Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems, pits, cellars, water and the ground.
  3. Limiting spread: Use oil blocks to prevent the surface spread of oil.
  4. Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents. NOTE: Do not flush oil away with water or aqueous cleaning agents.

00...... RAISING VEHICLE WITH TROLLEY JACK

IMPORTANTObserve the following trolley-jack-related instructions: Use only BMW-distributed/approved trolley jacks which have rubber plate contact points. Trolley jacks must be regularly serviced and always checked for functional reliability before they are used! Check the rubber plate on the trolley jack prior to each us replacing if necessary.

Scheme 1

Scheme 1
Scheme 1
WARNINGThe vehicle may be raised with a trolley jack only at the following jacking points!

Scheme 2

Scheme 2
Scheme 2
  1. Car jacking point
  2. Side car jacking points
  3. Rear differential Risk of damage: It is not permitted to raise the vehicle at the rear differential cover!

Scheme 3

Scheme 3: 31.... FRONT AXLE OVERVIEW
Scheme 3: 31.... FRONT AXLE OVERVIEW

Scheme 4

Scheme 4: 31.... LAYOUT OF SPRING STRUT SHOCK ABSORBER
Scheme 4: 31.... LAYOUT OF SPRING STRUT SHOCK ABSORBER

Scheme 5

Scheme 5: 31 00... FRONT AXLE + STEERING: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE CARRIED OUT AFTER THE FOLLOWIN
Scheme 5: 31 00... FRONT AXLE + STEERING: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE CARRIED OUT AFTER THE FOLLOWIN

A wheel/chassis alignment check must be carried out after the following work

  1. Release of following screw/bolt connections: Steering gear to front axle carrier Control arm to front axle carrier Support bearing to body (if centering pin is missing) Tie rod end to tie rod
  2. Replacement of following parts: Front axle carrier Steering gear Gaiter (if the tie rod end has to be screwed off) Control arm Support bearing (if centering pin is missing) Swivel bearing Tie rod end Tie rod

31 00... INFORMATION ON REPLACING SHOCK ABSORBERS

Facts

When a shock absorber is faulty on one side (leaking, noises, limit values exceeded on the shock tester), often both shock absorbers on the axle in question are replaced.

Consequence

This is not necessary for technical reasons and causes the manufacturer not to recognize the unnecessarily removed shock absorbers as damaged parts. Unnecessarily high costs for the customer can be avoided by replacing the shock absorber on one side only.

Procedure

Shock absorbers may be replaced on one side only until they have completed 50 000 km service.

Exception: On all M-models, when a limit value is exceeded on one side, it is still necessary always to replace both shock absorbers on the relevant axle.

31 00... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINUM)

Due to the chemical and corrosion characteristics of aluminum, always comply with the following points when handling aluminum components

  1. Do not bring into contact with battery acid!
  2. Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel bristles!
  3. Do not expose to flying sparks when grinding/separating! Cover components!
  4. Do not strike with steel welding splashes! Cover components!
  5. Do not expose to temperatures > 80 °C, even for brief periods! Temperatures in paint facilities do not have the same impact

31 00... INSTRUCTIONS (DAMAGE TO SUSPENSION)

Substandard roadholding, atypical noises, tires worn on one side, camber and toe-in values which deviate from nominal value and mis-shaped components are all indicators of damage to the suspension caused by road traffic accidents or similar impacts.

To repair vehicle correctly, depending on condition of vehicle, perform the following troubleshooting procedure

You must also follow the rules and guidelines for accident-related repairs to the steering gear.

Troubleshooting

Vehicle conditionPossible causeRemedy
1 Camber inside/toe-in outside the nominal value, adjustment of track alignment possibleA) Screw connection not OKA) Check screw connections: Tie rod end to swivel bearing Tie rod to power steering gear Power steering gear to front axle carrier
B) Tie rod or journal of tie rod end is deformedB) Replace tie rod, tension strut and swivel bearing IMPORTANT: If the journal of the tie rod end is deformed, the power steering gear must also be replaced
C) One or both tension struts is/are deformedC) Replace tension strut and swivel bearing
D) Control arm deformedD) Replace control arm, tension strut and swivel bearing
2 Camber inside/toe-in outside the nominal value, adjustment of track alignment possiblePowerful forces acting on steering/front axle componentsReplace tie rods Replace swivel bearing Replace power steering gear Replace tension strut Replace control arms
3 Camber/toe-in outside the nominal value, adjustment of track alignment not possiblePowerful forces acting on front axle with distortion of
A) Screw connectionsA) Check screw connections, replace the relevant part if necessary
B) Front axle supportB) Replace front axle carrier
C) See Pt. 1 b) to d)C) See Pt. 1 b) to d)
D) Spring strut/piston rodD) Replace spring strut
IMPORTANT
If the journal of the tie rod end is deformed, the power steering gear must also be replaced

TROUBLESHOOTING CHART

31 00... NOTES ON REPAIRING THREADS

IMPORTANTInstall Heli-coil thread inserts so that they are flush with the original thread.

Note. Damaged threads in engine carrier may be repaired with Heli-coil thread inserts. Comply with the procedure described in the example.

Scheme 6

Scheme 6
Scheme 6

Procedure

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. Create a clean core hole; if necessary, drill out screw remnants
  2. Create locating thread for Heli-coil thread insert
  3. Pick out Heli-coil thread insert in accordance with the table and screw into the locating thread until flush with the original thread
  4. Break drive pin and remove

31 10 000 REMOVING AND INSTALLING COMPLETE FRONT AXLE (WITH SPRING STRUT SHOCK ABSORBER)

WARNINGDanger to life! Secure engine in installation position to prevent it from falling down. See 11 00 670 SECURING ENGINE IN INSTALLATION POSITION (S85) .
IMPORTANTAdhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic system. Seal off hydraulic lines with plugs.

Necessary preliminary tasks

  1. Disconnect battery negative lead. See «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(ref-264851-S07594066352007091800000) .
  2. Draw off and dispose off hydraulic fluid from fluid reservoir
  3. Secure engine in installation position. See «11 00 670 SECURING ENGINE IN INSTALLATION POSITION (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-repair__11-00-670-securing-engine-in) .
  4. Remove front wheels
  5. Disconnect plug connection of both «PULSE GENERATORS»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-52-525-replacing-one-front)
  6. Remove and tie back brake caliper on both sides. See «34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FRONT BRAKE CALIPER»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-11-519-removing-and-installingreplacing) .
  7. Remove «reinforcement plate»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-10-010-removing-and-installingreplacing)
  8. If necessary, remove steering gear cover on both sides
  9. Remove wheel suspension cover on both sides
  10. Remove lower steering spindle from power steering gear. See «32 31 070 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING SPINDLE»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-070-removing-and-installing) .
  11. If necessary, disconnect plug connection on EH converter and expose line up to engine carrier.
  12. If necessary, disconnect plug connection on ride-height sensor and expose line up to engine carrier.
  13. If necessary, expose and disconnect vacuum line for engine mount up to point of separation on engine support arm.
  14. Except M5, M6: Remove pressure line and if necessary Dynamic Drive pressure line from vane pump.
  15. M5, M6: Disconnect pressure line from power steering gear. See «32 13 060 REMOVING AND INSTALLING/REPLACING POWER STEERING GEAR»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-13-060-removing-and-installingreplacing) .
  16. Disconnect return line from power steering cooler. See «32 41... NOTES ON HYDRAULIC LINE WITH QUICK-CONNECT COUPLING»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair)
  17. Remove stabilizer link on both sides from bracket/spring strut. See «31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR LEFT/RIGHT STABILIZER»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-35-005-removing-and-installingreplacing) .

Version with Dynamic Drive

Release nuts (1, 2).

Tighten to specified torque. See FRONT AXLE - TORQUE SPECIFICATIONS .

Scheme 11

Scheme 11
Scheme 11

Version with active steering

Disconnect plug connections (1, 2).

Expose wiring harness (3) up to front axle carrier.

Scheme 12

Scheme 12
Scheme 12
IMPORTANTGuide spring struts with your hand when lowering and raising in order to avoid damaging the wheel arches. After lowering, the spring struts must be aligned to the front axle carrier and secured in such a way that the ball joints of the control arms, tension struts and tie rod ends are not damaged.

Remove spring strut from spring strut dome.

Support front axle carrier, release from engine carrier and carefully lower with spring struts.

Scheme 13

Scheme 13
Scheme 13

After installation

  1. Fill and bleed hydraulic system. See «32 13 006 BLEEDING POWER STEERING UNIT»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-13-006-bleeding-power-steering) .
  2. Check pipe connections for leaks.
  3. Carry out wheel alignment check if a spring strut with support bearing was or has been installed without centering pin. See «32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-00-150-kds-chassiswheel-alignment) .
  4. Carry out steering angle sensor adjustment/adjustment for active front steering. Connect vehicle to BMW diagnosis system or Software Service Station.
  5. If necessary, carry out initial Dynamic Drive operation.

31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE

IMPORTANTObserve safety instructions for raising the vehicle Driving without reinforcement plate is not permitted!

Necessary preliminary tasks

  1. Remove underbody protective plate. See «51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-490-removing-and-installing) or «51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-491-removing-and-installingreplacing) .

Release screws (1) and remove reinforcement plate.

Installation

Replace screws and insertion nuts.

Tighten to specified torque. See 31 10 9AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 14

Scheme 14
Scheme 14

Replacement

If applicable, remove heat shield.

51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION

All except M5

Release screws (1 and 2) and pull out underbody protection (3) from under bumper trim.

Installation

Ensure that seals are correctly seated.

Center underbody protection (3) and tighten down screws (1) and (2).

Scheme 15

Scheme 15: 51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION
Scheme 15: 51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION

Replacement

If necessary, remove catches (1) on cover (2).

Scheme 16

Scheme 16
Scheme 16

Version with rough road package

Release screws (1 and 2).

Feed out underbody protection (3) towards rear.

Installation

Replace screws (1).

Tighten to specified torque. See FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 17

Scheme 17
Scheme 17

M5 only

Release screws (1 and 2).

Release screws (3) at side from wheel arch trim.

Pull underbody protection (4) forward under bumper trim.

Installation

Ensure that seals are correctly seated.

Center underside protection (4) and tighten down screws (1, 2 and 3).

Scheme 18

Scheme 18
Scheme 18

51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION

Necessary preliminary tasks

  1. Remove «front underbody protection»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__51-47-490-removing-and-installing) .

Not M5

Unfasten screws (1... 3).

Press heat shield (5) back.

Release screws (4) and remove underbody protection (6).

Installation

Ensure correct seating.

Center underbody protection (6) and tighten down all screws.

Scheme 19

Scheme 19
Scheme 19

M5 only

Unfasten screws (1 and 2).

Remove underbody protection (3).

Installation

Ensure correct seating.

Center underbody protection (3) and tighten down all screws.

Scheme 20

Scheme 20
Scheme 20

31 11 001 REPLACING FRONT AXLE CARRIER (M5, M6)

WARNINGDanger to life! Secure engine in installation position to prevent it from falling down.

Necessary preliminary tasks

  1. Disconnect battery negative lead. See «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair) .
  2. Secure engine in installation position. See «11 00 670 SECURING ENGINE IN INSTALLATION POSITION (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-repair__11-00-670-securing-engine-in) . Remove front wheels.
  3. Remove «stabilizer»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-35-000-removing-and-installingreplacing) .
  4. Remove «reinforcement plate»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-10-010-removing-and-installingreplacing) .
  5. Remove steering gear cover on both sides.
  6. Remove wheel suspension cover on both sides.
  7. Remove lower steering spindle from power steering gear. See «32 31 070 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING SPINDLE»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-070-removing-and-installing) .
  8. Disconnect plug connection on EH converter and expose line up to engine carrier.
  9. Disconnect plug connection on ride-height sensor and expose line up to engine carrier.
  10. Remove «tension strut on both sides from front axle carrier»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-12-080-removing-and-installingreplacing) .
  11. Remove jointed rod of ride-height sensor from control arm
  12. Remove «control arm on both sides from front axle carrier»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-12-000-removing-and-installingreplacing) .
  13. Remove left tie rod from power steering gear. See «32 21 151 REPLACING LEFT OR RIGHT TIE ROD»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-21-151-replacing-left-or) .
  14. Remove right tie rod end from swivel bearing. See «32 21 151 REPLACING LEFT OR RIGHT TIE ROD»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-21-151-replacing-left-or) .
  15. Detach heat shield for power steering gear from front axle carrier
  16. Remove power steering gear from front axle carrier and tie up. See «32 13 060 REMOVING AND INSTALLING/REPLACING POWER STEERING GEAR»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-13-060-removing-and-installingreplacing) .

Lower front axle carrier , move sideways and remove.

Modify heat shield(s).

Modify both engine mounts. See ENGINE SUSPENSION .

Modify jacking point.

Installation

Use previous front axle subframe as a template for modifying or replacing small parts.

Scheme 21

Scheme 21
Scheme 21

After installation

  1. Perform chassis alignment check. See «32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-00-150-kds-chassiswheel-alignment) .
  2. Carry out steering angle sensor adjustment.

31 11 506 LOWERING/RAISING FRONT AXLE CARRIER

Special tools required

  1. 00 2 030
  2. 00 2 040
  3. 31 4 012
  4. 33 3 274
WARNINGDanger to life! Secure engine in installation position to prevent it from falling down. See 11 00 670 SECURING ENGINE IN INSTALLATION POSITION (S85) .
IMPORTANTAdhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic system. Seal off hydraulic lines with plugs.

Necessary preliminary tasks

  1. Secure engine in installation position. See «11 00 670 SECURING ENGINE IN INSTALLATION POSITION (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-repair__11-00-670-securing-engine-in) .
  2. Remove «reinforcement plate»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-10-010-removing-and-installingreplacing) .
  3. If necessary, remove steering gear cover on both sides.
  4. If necessary, remove wheel suspension cover on both sides.
  5. Remove lower steering spindle from power steering gear. See «32 31 070 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING SPINDLE»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-070-removing-and-installing) .
  6. If necessary, disconnect plug connection on EH converter and expose line up to engine carrier.
  7. If necessary, disconnect plug connection on ride-height sensor and expose line up to engine carrier.
  8. If necessary, unclip vacuum line for engine mount on engine support arm.

Version with Dynamic Drive

Draw off and dispose off hydraulic fluid from fluid reservoir.

Release nut (1) for Dynamic Drive return line. Tightening torque 35 Nm.

Release nut (2) for Dynamic Drive pressure line. Tightening torque 30 Nm.

Release nuts (3) for pressure lines to front axle oscillating motor. Tightening torque 30 Nm.

Scheme 22

Scheme 22
Scheme 22

Version with active steering

Disconnect plug connections (1, 2).

Expose wiring harness (3) up to front axle carrier.

WARNINGDanger of injury! Failure to comply with the following instructions may result in the vehicle slipping off the lifting platform and critically injuring other persons.

When supporting components, make sure that

  1. the vehicle can no longer be raised or lowered
  2. the vehicle does not lift off the locating plates on the lifting platform

If necessary, position special tool 00 2 040 with a 2nd person helping on workshop jack 00 2 030.

Insert special tool 31 4 012 into corresponding receptacles of special tool 00 2 040.

Align special tool 00 2 040 to front axle carrier.

Note. Make sure when raising that the special tools 31 4 012 are correctly inserted in the rear recesses on the front axle carrier. Support front axle carrier in rear area by raising special tool 00 2 040. Position special tool 33 3 274 on floor jack mounting.

Scheme 23

Scheme 23
Scheme 23
IMPORTANTPay attention to power steering hoses and lines when lowering and raising. Hoses/lines must not be kinked/tensioned/bent! When lowering and raising, make sure the cover for the relevant tension strut rubber mount is free to move.

Release screws (1, 2).

Installation

Check threads for damage; if necessary, repair with Heli-coil thread inserts.

Tighten down screws (1) and then screws (2).

Tighten to specified torque. See FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 24

Scheme 24
Scheme 24
IMPORTANTRisk of damage! The following operation must be carried out during lowering: N54 with automatic transmission: Release screws (1) and remove bracket (2) for transmission oil cooler lines from front axle carrier

Lower front axle carrier 100 mm.

Scheme 25

Scheme 25
Scheme 25

After installation

  1. Version with Dynamic Drive: Fill and bleed hydraulic system. See «32 13 006 BLEEDING POWER STEERING UNIT»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-13-006-bleeding-power-steering) . Check pipe connections for leaks
  2. Carry out steering angle sensor adjustment/adjustment for active front steering
  3. Carry out initial Dynamic Drive operation

31 12 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CONTROL ARM

Note. If the control arm is detached from the front axle carrier, it is necessary after reinstallation to carry out a wheel/chassis alignment check.

Necessary preliminary tasks

  1. If necessary, remove steering gear cover at side

Right side only on version with xenon headlight

Release nut (jointed rod on control arm).

Remove jointed rod (1) from control arm.

Disconnect plug connection (2) on ride-height sensor.

Scheme 26

Scheme 26
Scheme 26

Unscrew nut (1).

Remove screw towards rear.

Only on right side: If necessary, remove holder with ride-height sensor.

Installation

Replace self-locking nut.

Tightening torque, see 31 12 2AZ in 31 12 CONTROL ARMS AND STRUTS .

Release nut (2); if necessary, grip at Torx socket.

Take off control arm.

Scheme 27

Scheme 27
Scheme 27

Installation

Keep control arm to swivel bearing connection clean and free from oil and grease.

Replace self-locking nut.

Tightening torque, see 31 12 6AZ in 31 12 CONTROL ARMS AND STRUTS .

After installation

  1. Perform chassis alignment check
  2. Carry out steering angle sensor adjustment/adjustment for active front steering

31 12 080 REMOVING AND INSTALLING/REPLACING BOTH TENSION STRUTS

Special tools required

  1. 31 2 230

Note. On M models replace trailing links in pairs.

Necessary preliminary tasks

  1. Remove front wheels
  2. Remove front assembly underside protection. See «51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-490-removing-and-installing) .
  3. If necessary, remove steering gear cover on both sides.
  4. If necessary, remove wheel suspension cover.
  5. Remove «stabilizer links from stabilizer»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-35-005-removing-and-installingreplacing) .
  6. Remove «control arm from swivel bearing»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-12-000-removing-and-installingreplacing) .

Release nut (1) and remove bolt (3).

Installation

Replace self-locking nut.

Tighten bolt connection in normal position.

Tighten to specified torque. See 31 12 1AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Slacken nut (2).

Scheme 28

Scheme 28
Scheme 28

Installation

Keep tension strut to swivel bearing connection clean and free from oil and grease.

Replace self-locking nut.

Tighten to specified torque. See 31 12 19AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Support swivel bearing with workshop jack and a suitable mounting.

Release nut and expand swivel bearing with special tool 31 2 230.

Lower swivel bearing approx. 2.5 cm and remove tension strut.

Installation

Keep press fit of swivel gearing and spring strut in lower area clean and free from oil and grease.

Spread swivel bearing with special tool 31 2 230, align by means of gap to web on back of spring strut and raise as far as it will go. Tightening torque, see 31 31 3AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 29

Scheme 29
Scheme 29

31 12 138 REPLACING RUBBER MOUNTS ON BOTH TENSION STRUTS

Special tools required

  1. 31 3 031
  2. 31 3 032
IMPORTANTThe rubber mounts on both tension struts must be replaced! Note that the rubber mounts may only be changed once.

Necessary preliminary tasks

  1. Check ball joints of tension struts while installed, replace «tension struts»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-12-080-removing-and-installingreplacing) if necessary.
  2. Remove «tension struts»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-12-080-removing-and-installingreplacing) .
IMPORTANTIf the tension struts already feature an identification mark with a center punch, it is necessary to replace both tension struts.

Mark tension struts with a punch mark in area (A).

Scheme 30

Scheme 30
Scheme 30

Using a press and special tools 31 3 031 and 31 3 032, press rubber mount out of tension strut.

Note. Special tool 31 3 031 must be exactly flush with rubber mount bushing.

Scheme 31

Scheme 31
Scheme 31

Installation

Keep rubber mount and bushing in tension strut clean and free from grease.

Align rubber mount by way of arrow to marking on tension strut and press in. The deviation must not exceed ± 5°.

Scheme 32

Scheme 32
Scheme 32

Installation

Protrusion (A) equally large.

Scheme 33

Scheme 33
Scheme 33

31 21 090 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SWIVEL BEARING

Special tools required

  1. 31 2 230

Necessary preliminary tasks

  1. Remove front brake disc. See «34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-11-220-removing-and-installingreplacing) .
  2. Remove front pulse generator from swivel bearing. See «34 52 525 REPLACING ONE FRONT PULSE GENERATOR»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-52-525-replacing-one-front) .
  3. Remove «control arm from swivel bearing»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-12-000-removing-and-installingreplacing) .
  4. Remove tie rod end from swivel bearing. See «32 21 151 REPLACING LEFT OR RIGHT TIE ROD»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-21-151-replacing-left-or) .
  5. Remove «bracket for stabilizer link from swivel bearing»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-35-007-removing-and-installingreplacing) .
  6. Remove «tension strut from swivel bearing»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-12-080-removing-and-installingreplacing) .

E63, E64: Spread swivel bearing with special tool 31 2 230.

Lower swivel bearing with workshop jack.

Installation

Keep press fit of swivel gearing and spring strut in lower area clean and free from oil and grease.

Spread swivel bearing with special tool 31 2 230, align by means of gap to web on back of spring strut and raise as far as it will go.

Scheme 34

Scheme 34
Scheme 34

Replacement

Modify or if necessary replace wheel bearing .

After installation

  1. Replacement only: Perform chassis alignment check

31 21 180 REPLACING BEARINGS (WHEEL HUB) FOR FRONT WHEEL

Necessary preliminary tasks

  1. Remove «swivel bearing»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-21-090-removing-and-installingreplacing) .
IMPORTANTWhen clamping swivel bearing unit, make sure it is only clamped at wheel bearing.

Clamp swivel bearing as illustrated.

Scheme 35

Scheme 35
Scheme 35

Release screws and remove swivel bearing upwards.

Scheme 36

Scheme 36
Scheme 36

Keep tapped holes (1) clean and free from grease.

Keep contact surface (2) of wheel bearing and swivel bearing clean and free from grease.

Installation

If the wheel bearing is not replaced, all the tapped holes (1) in the wheel bearing must be reconditioned.

Replace screws.

Tighten to specified torque. See 31 12 5AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 37

Scheme 37
Scheme 37

Facts

When a shock absorber is faulty on one side (leaking, noises, limit values exceeded on the shock tester), often both shock absorbers on the axle in question are replaced.

Consequence

This is not necessary for technical reasons and causes the manufacturer not to recognize the unnecessarily removed shock absorbers as damaged parts. Unnecessarily high costs for the customer can be avoided by replacing the shock absorber on one side only.

Procedure

Shock absorbers may be replaced on one side only until they have completed 50 000 km service.

Exception: On all M-models, when a limit value is exceeded on one side, it is still necessary always to replace both shock absorbers on the relevant axle.

31 31 000 REMOVING AND INSTALLING COMPLETE LEFT OR RIGHT SPRING STRUT SHOCK ABSORBER

IMPORTANTIf the centering pin is missing from the support bearing, the position of the studs to the wheel arch must be marked so that the original camber is approximately maintained. Only one nut may ever be released for marking.

Necessary preliminary tasks

  1. Remove «swivel bearing»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-21-090-removing-and-installingreplacing)

M5

Disconnect plug connection (2).

Unclip connecting cable (1) from spring strut dome cover (3).

Detach connecting cable (1) from spring strut.

Scheme 38

Scheme 38
Scheme 38

If necessary, release expander rivet (1).

If necessary, unclip spring strut dome cover (2) from front cross-strut.

Scheme 39

Scheme 39
Scheme 39

Centering pin missing: Make position of studs in relation to wheel arch.

Secure spring strut against falling out.

Unscrew nuts.

Remove spring strut downwards out of wheel arch.

Installation

Align spring strut using centering pin to bore in wheel arch or studs to wheel arch and push upwards.

Replace self-locking nuts.

Tighten to specified torque. See 31 31 1AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 40

Scheme 40
Scheme 40

After installation

  1. Carry out wheel alignment check if a spring strut with support bearing was or has been installed without centering pin.

31 31 031 REPLACING FRONT LEFT OR RIGHT SPRING STRUT (M Models)

Special tools required

  1. 31 3 340
  2. 31 3 341
  3. 31 3 355
  4. 31 3 381
WARNINGObserve the following instructions to avoid any risk of injury by the coil springs.
  1. Prior to each use, check the special tools for defects, modifications and operational reliability.
  2. Damaged/modified special tools must not be used!
  3. No changes or modifications may be made to the special tools!
  4. These special tools are intended solely for the purpose of tightening and relieving cylindrical and tapered suspension springs.
  5. Keep special tools dry, clean and free of grease.
  6. Impact screwdrivers may not be used!
  7. Do not compress coil spring to full extent.
  8. Observe manufacturer's instructions.

Note. Read and comply with Information on replacing shock absorbers.

In a warranty case you must always provide a fault memory printout, even where there is no fault memory entry, with the defective part.

Necessary preliminary tasks

  1. Remove «front spring strut»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-31-000-removing-and-installing) .

Removing

Clamp special tool 31 3 341 in vice.

Fit special tools 31 3 381 and 31 3 355 from above on special tool 31 3 341 until locking pins (1) can be felt and heard to snap into place.

Check seating of special tools 31 3 381 and 31 3 355, correct if necessary.

Scheme 41

Scheme 41
Scheme 41
WARNINGDuring tensioning, upper coil of coil spring must rest completely in recess of special tool 31 3 355! Compress coil spring until stress on piston rod is relieved.

Clean coil spring to remove coarse contamination and take up with special tools 31 3 381 and 31 3 355.

Turn spring strut until lower end of coil spring rests centrally in opening of special tool 31 3 381.

WARNINGUpper coil of coil spring must rest completely in recess of special tool 31 3 355!

Compress coil spring until stress on piston rod is relieved.

Scheme 42

Scheme 42
Scheme 42

Release nut (1), gripping piston rod if necessary.

Scheme 43

Scheme 43
Scheme 43

Remove joint seat (1), support bearing (2), spring cup (3) with bearing, spring pad (4) and gaiter (5).

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45

Relieve tension on coil spring and remove.

Scheme 46

Scheme 46
Scheme 46

If necessary, remove support disc (1), auxiliary damper (2) and spring pad (3) from shock absorber. Remove shock absorber from special tool 31 3 381.

Installation

Check auxiliary damper (2) and lower spring pad (3) for damage, replace if necessary.

Note. Align spring pad (3) by way of recess to spring cup.

Scheme 47

Scheme 47
Scheme 47

Hold shock absorber and coil spring with special tools 31 3 381 and 31 3 355.

Turn coil spring until lower end of coil spring rests centrally in opening of special tool 31 3 381.

WARNINGDo not compress coil spring to full extent. The shown coil of the coil spring must rest completely in recess of special tool 31 3 355!

Tension coil spring.

Scheme 48

Scheme 48
Scheme 48

Check installation position of spring pad, if necessary relieve tension on coil spring and correct installation position.

Check support bearing (2), upper spring plate (3) with bearing, spring pad (4) and gaiter (5) for damage, replace if necessary.

Attach spring cup (3) with bearing and spring pad (4) with gaiter (5) to piston rod.

Attach support bearing (2) and joint seat (1) to piston rod.

Note. Joint seat is correctly seated in support bearing mounts after tension is relieved on coil spring.

Replace nut and tighten down (gripping piston rod in so doing).

Tighten to specified torque. See 31 31 2AZ in FRONT AXLE - TORQUE SPECIFICATIONS .

IMPORTANTUpper coil of coil spring must rest positively on spring cup! Lower end of coil spring must be aligned centrally to opening in special tool 31 3 381.

Relieve tension on coil spring.

Check installation position of gaiter, correct fold if necessary.

Note. End of coil spring must not touch against shoulder of spring pad. The recess only serves to reinforce and correctly seat the spring pad and does not serve as a stop for the spring end.

After installation

  1. Carry out wheel alignment check if a spring strut with support bearing was or has been installed without centering pin.

51 71 373 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON SPRING STRUT DOME

IMPORTANTVehicles must not be driven without tension struts. Driving without tension struts will result in bodywork damage.

Necessary preliminary tasks

  1. Remove lower microfilter housing section on left/right. See «64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION»(/bmw/m5/e60e61-2004-2010/remont/automatic-hvac-system/#heating-air-conditioning-repair__64-31-061-removing-and-installingreplacing) .

If necessary, remove cover on spring strut dome on left/right

  1. Release expander rivets (1).
  2. Remove cover (3)
  3. taking care not to damage retaining lug (2)

Scheme 49

Scheme 49
Scheme 49

If necessary, remove tension strut panels

  1. Release expander rivets on panel (2)
  2. Remove panel (2) in direction of arrow

Scheme 50

Scheme 50
Scheme 50

Important - modified screw connection!

Screws must be replaced and - because of the modified surface coating - tightened to increased torque!

Release screws (1).

Remove tension strut (2).

Installation

Replace screws.

Tighten to specified torque, 27 Nm

Scheme 51

Scheme 51
Scheme 51

31 33 001 REPLACING FRONT LEFT OR RIGHT SPRING STRUT SUPPORT BEARING (M5, M6)

Replacement: If necessary, twist out centering pin (1).

Note. If a support bearing (2) was fitted without centering pin (1), the centering pin (1) of the new support bearing (2) must be twisted out.

Scheme 52

Scheme 52: 31 33 001 REPLACING FRONT LEFT OR RIGHT SPRING STRUT SUPPORT BEARING (M5, M6)
Scheme 52: 31 33 001 REPLACING FRONT LEFT OR RIGHT SPRING STRUT SUPPORT BEARING (M5, M6)

31 33 095 MEASURING RIDE-LEVEL HEIGHT OF VEHICLE

Necessary preliminary tasks

  1. Move vehicle into normal position

Determine actual ride height (A) - to do so, attach tape measure to rim flange (2) at bottom middle and measure to lower edge of wheel arch (1).

Scheme 53

Scheme 53
Scheme 53

31 33 100 REMOVING AND INSTALLING/REPLACING COIL SPRING FOR FRONT LEFT OR RIGHT SPRING STRUT (M5, M6)

IMPORTANTFor safety reasons, both coil springs on the relevant axle must always be replaced on motorsport vehicles!

Note. The coil spring is assigned after the vehicle identification number has been entered and the optional extras of the relevant vehicle selected (refer to electronic spare parts catalogue).

After installation

  1. Carry out wheel alignment check if a spring strut with support bearing was or has been installed without centering pin.

31 35 000 REMOVING AND INSTALLING/REPLACING FRONT STABILIZER

Necessary preliminary tasks

  1. Remove front assembly underside protection. See «51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-490-removing-and-installing) .
  2. If necessary, remove wheel suspension cover on both sides
  3. Remove «stabilizer link on both sides from stabilizer»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-35-005-removing-and-installingreplacing)

If necessary, remove holder for hydraulic lines from retaining bracket.

Release nut (1) and screw (2) at both ends.

Remove stabilizer from front axle carrier.

Installation

Check both rubber mounts for damage, replace if necessary.

Replace self-locking nuts.

Tighten to specified torque. See 31 35 1AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 54

Scheme 54
Scheme 54

Replacement

Remove rubber mount on both sides from stabilizer.

31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR LEFT/RIGHT STABILIZER

Note. Stabilizer links may only be replaced in pairs.

Necessary preliminary tasks: Remove front wheel

  1. Release nuts (1, 2); if necessary, grip at Torx socket.

Remove stabilizer link.

Installation

Replace self-locking nuts.

Tighten to specified torque. See 31 35 11AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 55

Scheme 55
Scheme 55

31 35 007 REMOVING AND INSTALLING/REPLACING HOLDER FOR LEFT OR RIGHT PUSH ROD/STABILIZER

Remove front wheel.

Remove stabilizer link from holder (1).

Release screw (2). Tightening torque, see 31 35 10AZ in 31 35 STABILIZER BAR .

Scheme 56

Scheme 56: 31 35 007 REMOVING AND INSTALLING/REPLACING HOLDER FOR LEFT OR RIGHT PUSH ROD/STABILIZER
Scheme 56: 31 35 007 REMOVING AND INSTALLING/REPLACING HOLDER FOR LEFT OR RIGHT PUSH ROD/STABILIZER

Support swivel bearing with workshop jack and a suitable mounting.

Unscrew nut (1).

Remove holder (2) for brake hose, pulse generator and if necessary brake pad sensor.

Remove screw (4) with holder (3) towards front.

Installation

Replace self-locking nut.

Tighten to specified torque. See 31 31 3AZ in FRONT AXLE -- TORQUE SPECIFICATIONS .

Scheme 57

Scheme 57
Scheme 57

31 35 021 REPLACING RUBBER MOUNTS OF STABILIZER RETAINING FIXTURE ON FRONT AXLE CARRIER

Necessary preliminary tasks

  1. Remove «stabilizer from front axle carrier»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-35-000-removing-and-installingreplacing)

Remove retaining bracket (1), if necessary retaining plate (3) and rubber mount (2) on both sides.

Installation

Keep retaining bracket (1), rubber mount (2) and stabilizer clean and free from oil and grease.

Version with Dynamic Drive: Keep contact face for rubber mount on anti-friction bearing clean and free from oil and grease.

Scheme 58

Scheme 58
Scheme 58

31 90... FRONT AXLE TROUBLESHOOTING

Follow troubleshooting for steering/shock absorbers.

FaultCauseRemedy
Grinding noise (louder when negotiating bends)Wheel bearings faultyReplace wheel bearings
VibrationWheel imbalanceBalance wheels
Radial/lateral rim runoutCheck rims, replace if necessary
Radial tire runoutMatch or replace tires
Steering-wheel shakeWheel imbalanceBalance wheels
Radial/lateral rim runoutCheck rims, replace if necessary
Rubber mount of control arm faultyReplace control arms
Ball joint in control arm wornReplace control arms
Rubber mount of tension strut faultyReplace rubber mounts on both tension struts
Ball joint on tension strut wornReplace both tension struts
Refer to TROUBLESHOOTING for steering
Excessive steering wheel play/steering wheel inclinationRubber mount of control arm faultyReplace control arms
Ball joint in control arm wornReplace control arms
Rubber mount of tension strut faultyReplace rubber mounts on both tension struts
Ball joint on tension strut wornReplace both tension struts
Refer to TROUBLESHOOTING for steering
Rattling noiseBolts for reinforcement plate looseTighten down bolts (refer to REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE )
Bolts for front axle carrier to engine carrier looseReplace bolts
Bolt for spring strut to swivel bearing looseReplace bolt & nut
Ball joint in control arm wornReplace control arms
Ball joint on tension strut wornReplace both tension struts
Rubber mounts for stabilizer bar bracket faultyReplace both rubber mounts of stabilizer bar bracket
Ball joints on stabilizer link(s) wornReplace both stabilizer links
Excessive tire wearFront or rear axle alignment incorrectly adjustedCheck suspension components for damage; if necessary, carry out chassis/wheel alignment check

TROUBLESHOOTING CHART

31 90... TROUBLESHOOTING SHOCK ABSORBER

Read and comply with Information on replacing shock absorbers.

FaultCauseRemedy
Shock absorber knocking (bottoming)Rubber damper faultyVisually inspect auxiliary spring for cracking, replace auxiliary spring
Shock absorber leaking (oil/gas)Replace shock absorber
Rattling noiseShock absorber mounting looseTighten shock absorber
Support bearing faulty/hardenedReplace support bearing
Shock absorber leaking (oil/gas)Replace shock absorber
Worn down areas (flattened areas) on tire profileShock absorber leaking (oil/gas)Replace shock absorber
Long after-swinging of body after driving over rough roadShock absorber leaking (insufficient shock absorber effect)Replace shock absorber
Building-up of body in case of successive uneven surfacesShock absorber leaking (insufficient shock absorber effect)Replace shock absorber
Wheels jumping even on normal road surfacesShock absorber leaking (insufficient shock absorber effect)Replace shock absorber
Whistling noisesSeparating skin in vent holes of auxiliary springRemove separating skin

TROUBLESHOOTING

See also:
• 11 00 670 SECURING ENGINE IN INSTALLATION POSITION (S85)
• PULSE GENERATORS
• 34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FRONT BRAKE CALIPER
• 32 31 070 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING SPINDLE
• 32 13 060 REMOVING AND INSTALLING/REPLACING POWER STEERING GEAR
• 32 41... NOTES ON HYDRAULIC LINE WITH QUICK-CONNECT COUPLING
• 51 71... REMOVING AND INSTALLING/REPLACING FRONT (BOTTOM) RIGHT WHEEL ARCH TRIM
• FRONT AXLE - TORQUE SPECIFICATIONS
• 32 13 006 BLEEDING POWER STEERING UNIT
• 32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION
• 51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION
• 51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
• 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD
• 32 21 151 REPLACING LEFT OR RIGHT TIE ROD
• ENGINE SUSPENSION
• 31 12 CONTROL ARMS AND STRUTS
• 34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS (S85)
• 34 11 250 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD PLATE AT FRONT
• 64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION
• 31 35 STABILIZER BAR
• reinforcement plate
• 31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR LEFT/RIGHT STABILIZER
• front underbody protection
• stabilizer
• tension strut on both sides from front axle carrier
• control arm on both sides from front axle carrier
• front axle carrier
• bracket for stabilizer link from swivel bearing
• wheel bearing
• swivel bearing
• front spring strut
• 31 31 031 REPLACING FRONT LEFT OR RIGHT SPRING STRUT (M Models)
• rubber mounts
• TROUBLESHOOTING

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