Brakes - Repair BMW M5 E60/E61

34 00... CHECKING BRAKE DISCS

Special tools required

1. 34 1 280

See BRAKES - SPECIAL TOOLS .

Necessary preliminary tasks

1. Remove wheels

Checking thickness difference

1. Measure thickness difference within brake surfaces at 8 point (spread over the circumference) with a micrometer gauge
2. Compare measurement result with setpoint value . See «BRAKES - TECHNICAL DATA»(ref-264583) .

Scheme 6

Check minimum brake disc thickness

1. Position special tool 34 1 280 at three measuring points in measuring area (1) and measure
2. Compare measurement result and lowest value with setpoint value . See «BRAKES - TECHNICAL DATA»(ref-264583) .

Scheme 7

34 00... GENERAL INFORMATION

The brake system is one of the most important safety systems on any motor vehicle. It is therefore essential to act with utmost care when working on the brake system and to follow the instructions below.

General

1. Ensure cleanliness and only use rags which do not lose lint.
2. Wash away or vacuum up brake dust, do not clear it away using compressed air. This dust is a health hazard.
3. Ensure that no oils or grease enter the brake system: these substances would cause complete failure of the entire brake system.
4. When cleaning brake components with brake cleaner, do not allow brake cleaner to get into the brake system.
5. Even the most minute traces of brake cleaner must be avoided.

Brake fluid

1. Replace brake fluid at least every two years.
2. Never re-use drained brake fluid.
3. Always use BMW-approved brake fluid, refer to «BRAKES - OPERATING FLUIDS»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-operating-fluids) .
4. Always dispose of brake fluid in approved receptacles.
5. Do not allow brake fluid to drain into drain pipes, into the outside environment or into unsuitable facilities. This would create the risk of groundwater contamination since brake fluid is classed as a fluid that is hazardous to water.
6. Do not allow brake fluid to come into contact with paintwork as this will destroy the paint.
7. Brake fluid must not be allowed to remain on bare skin too long in order to avoid skin problems. Wash skin coated with brake fluid with water and soap.
8. If brake fluid makes contact with eyes, immediately flush with large quantity of clean water and visit eye doctor.

Wheel brakes

1. Brake linings: Brake linings must be replaced when the warning threshold of the brake lining wear indicator is reached. Brake linings must always be replaced on both sides of any axle. The friction surfaces of the brake linings must not come into contact with oils or greases. The brake linings must be replaced if they are fouled by such substances. In the case of rotation-dependent brake linings, make sure the arrow marking points in the direction of rotation of the brake disk for when the vehicle is moving forward. Brake linings with left/right markings must be fitted on the relevant side of the vehicle. One-sided angled areas on the brake linings must be located on the disk contact side of the brake caliper for when the vehicle is moving forward.
2. Brake discs: Brake disks must not be scored or cracked. Furthermore, minimum brake disk thickness, disk runout, parallelism and surface roughness of the friction surfaces must not exceed or drop below the permitted values. Refer to «BRAKES - TECHNICAL DATA»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-technical-data) . Always strip preservative off new parts before installation. With the rear brake discs, also strip preservative off brake drum on parking brake.
3. Brake drums: Brake drums must not be scored or cracked. Furthermore, the maximum drum inside diameter, radial runout and surface roughness of the friction surfaces must not exceed or drop below the permitted values. Always strip preservative off new parts before installation.
4. Brake calipers: Only approved pastes on the basis of glycine must be used for repairs on brake calipers. All moving parts on the brake caliper must move freely: note grease specifications. Use only BMW-approved lubricants to grease caliper guides.

Brake lines, brake hoses: brake lining wear indicator

1. Brake lines and brake hoses must be correctly routed and must not abut with body or components in a way which would cause chafing.
2. To prevent damage, release and tighten brake line couplings with a special brake line wrench only.
3. The system must be bled each time any brake lines have been detached.
4. All connection points must be checked for leaks.
5. Only tighten down brake hoses on the front axle when wheels are in straight-ahead position.
6. Close open connections on brake lines and individual components to prevent dirt from entering the brake system.
7. Observe tightening torques when tightening down brake line screw connections. Tighten to specified torque. See «34 32 1AZ.»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-tightening-torques__34-32-brake-lines)

Wheel-slip control system

The slip control system is basically maintenance-free.

However, be sure to adhere to the following

1. When carrying out welding work with electric welding equipment, be sure to disconnect the plug from the electronic control unit (ignition turned off).
2. During painting work, the control unit may be subjected for brief periods to loads of max. 95 °C and for long periods (approx. 2 hours) to loads of max. 85 °C.
3. Tighten down the battery terminals completely.
4. The brake lines on the hydraulic unit must not be mixed up; if necessary, mark them before they are removed and after completing repairs perform the mix-up check with the DIS Tester.

34 00... GENERAL INFORMATION ON BREAKING IN NEW BRAKE DISCS / BRAKE PADS

34 00... TESTING AWD VEHICLES ON DYNAMIC BRAKE AND POWER ANALYZERS (E30, E34, E46, E53, E83, E60, E61, E90, E91, E92)

Note. Running AWD vehicles on dynamic brake analyzers is governed by different instructions, depending on the vehicle model.

In order to test AWD vehicles on dynamic brake analyzers, it is essential to follow various measures in accordance with the special instructions in Appendices 1 to 5 for the vehicles in question

1. E30 AWD
2. E34 AWD
3. E46 AWD
4. E53 X5
5. E83 X3
6. E60/E61 AWD
7. E90/E91/E92 AWD

34 00 009 BRAKE TEST ON BRAKE ANALYZER (TEST STAND) (S85)

Necessary preliminary tasks

1. Check tires for damage
2. Check tire treads
3. Check tire pressure

The brakes must be at normal operating temperature. For this purpose, gently warm up the brake disks/drums while dry by braking the vehicle several times.

Scheme 8

34 00 010 CHECKING THICKNESS OF BRAKE PAD

Special tools required

1. 34 1 260

Note. The thickness of the outer brake pads can be determined without removing the wheels.

If necessary, move car until opening for brake pad wear indicator (brake pad) can be seen through rim styling.

Insert special tool 34 1 260 through rim into opening for brake pad wear indicator.

Press special tool onto brake pad. Slide ring (1) in direction of arrow up to stop and read off measured value.

Note. Brake disk Brake pad with backplate

Safe limit for lining wear, front brake.

Safe limit for lining wear, rear brake.

Scheme 9

34 00 017 CHECKING BRAKE BOOSTER (LOW-PRESSURE TEST)

Special tools required

1. 34 3 100

Necessary preliminary tasks

1. Remove left microfilter housing

1. Detach hose from connection piece. Install vacuum tester 34 3 100 between connection piece and vacuum hose of non-return valve.
2. Start engine.
3. Check buildup of partial vacuum.
4. Switch off engine.
5. Press the brake pedal to set a vacuum pressure of not more than 0.8 bar and wait for the value to stabilize.
6. When the brake pedal is not pressed, the vacuum pressure is permitted to drop over a test period of 1 minute by max. 0.06 bar.

Scheme 10

If specified values are not reached

1. Check line connections for vacuum seal.
2. Replace non-return valve.
3. Check seal between brake booster and brake master cylinder (sealing ring) for perfect condition and correct seating.
4. If the specified values are not achieved when the test is repeated, you must replace the brake booster.

34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE SYSTEM

Necessary preliminary tasks

1. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .
2. Remove lower section of microfilter housing. See «64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION»(ref-379401-S13162676242010121300000) .

Connect bleeder unit to expansion tank and switch on.

Note. Check relevant Operating Instructions for each device. Charging pressure should not exceed 2 bar.

Scheme 11

Flushing brake system completely

Connect bleeder hose with collecting tray to bleeder valve on rear right brake caliper.

Open bleeder valve and purge until clear, bubble-free brake fluid emerges.

Close bleed valve.

Follow same procedure on rear left, front right and front left wheel brake.

Scheme 12

Note. The clutch slave cylinder must also be scavenged in vehicles with manual transmissions.

Switch off brake fluid changer and remove from expansion tank.

Check brake fluid level.

Close expansion tank.

Note. Pay attention to rubber seal (1) in sealing cap.

Scheme 13

34 00 050 BLEEDING BRAKE SYSTEM WITH DSC

Necessary preliminary tasks

1. Remove lower section of microfilter housing. See «64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION»(ref-379401-S13162676242010121300000) .
2. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .

Observe the filling and bleeding instructions when replacing or repairing

1. Brake master cylinder
2. Hydraulic unit
3. Components and connecting lines which are fitted between these assemblies.

Connect bleeder unit with max. 2 bar filling pressure.

A second person is needed to help carry out this work.

1. Connect BMW Diagnosis and Information System (DIS).
2. Select path: Service functions - Chassis/Suspension - Slip control systems - Bleeding procedure.
3. Connect bleeder unit to expansion tank and switch on.

Connect bleeder hose with collecting tray to bleeder valve on rear right brake caliper.

Open bleeder valve and purge until clear, bubble-free brake fluid emerges.

Close bleed valve.

Follow same procedure on rear left, front right and front left wheel brake.

Bleeding rear-axle brake circuit

Connect bleeder hose with collecting tray to bleeder valve on rear right brake caliper.

Close bleeder valve.

Run through bleeding routine with BMW Diagnosis and Information System (DIS) with bleeder valve open.

After completing routine, press brake pedal 5 times to floor, clear and bubble-free brake fluid must flow out.

Close bleed valve.

Repeat procedure at rear left.

Bleeding front-axle brake circuit

Connect bleeder hose with collecting tray to bleeder valve on front right brake caliper.

Close bleeder valve.

Run through bleeding routine with BMW Diagnosis and Information System (DIS) with bleeder valve open.

After completing routine, press brake pedal 5 times to floor, clear and bubble-free brake fluid must flow out.

Close bleed valve.

Repeat procedure at front left.

Scheme 14

Switch off brake fluid changer and remove from expansion tank.

Check brake fluid level.

Close expansion tank.

Note. Pay attention to rubber seal (1) in sealing cap.

Scheme 15

34 11 000 REMOVING AND INSTALLING/REPLACING BRAKE LININGS ON BOTH FRONT DISC BRAKES

Special tools required

1. 34 1 080
2. 34 1 280
3. 34 6 320

Necessary preliminary tasks

1. Remove wheels
2. Remove «brake pad wear sensor»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-35-001-replacing-a-brake)

Observe safety instructions on raising the vehicle. See 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM .

If necessary, when replacing linings, reset CBS display in accordance with factory specification.

Note. After completing work: Fully depress brake pedal several times so that brake linings contact brake discs. When installing new brake linings at front and rear axles, brake fluid level must be brought up to "MAX" marking. Read and comply with notes on breaking in new brake discs/ brake pads.

Lever out retaining spring (1) in direction of arrow towards rear.

Installation

Attach retaining spring (1) first at top and bottom and then allow retaining lug (2) to engage in recess of brake caliper housing.

Scheme 16

Remove plastic plugs (1).

Scheme 17

Left

Pull brake lining wear sensor (1) towards rear out of lining.

If necessary, replace brake lining wear sensor.

Release guide screws (2) with special tool 34 1 080. Withdraw brake caliper backwards.

Installation

Only clean guide screws; do not grease.

Check threads.

Replace all guide screws which are not in perfect condition.

Scheme 18

Press back brake linings and piston with special tool 34 6 320.

Scheme 19

Press brake linings inwards and remove.

The two brake linings are seated with a spring in the piston or in the brake caliper housing and must not be mixed up.

In the event of one-sided brake lining wear, do not change brake linings round.

Observe minimum thickness of brake linings.

Clean brake linings.

Do not apply grease to brake pad backplate.

Scheme 20

Note. The outer brake pads gradually need to be changed as well. The previous version (A) with retaining spring (1) is replaced by brake pads of version (B) without retaining spring! The use of pad sets of version (A) with retaining spring continues to be permissible!

Scheme 21

Check minimum brake disc thickness

1. Position special tool 34 1 280 at three measuring points in area (1) and measure.
2. Compare measurement result and lowest value with setpoint value.

New brake linings may only be installed if the brake disc thickness is greater than or equal to the minimum brake disc thickness (MIN TH).

Check dust sleeve (1) for damage and replace if necessary.

Clean contact face (2) of brake piston and apply a thin coating of anti-squeak compound.

Scheme 22

Clean mounting faces (1) and (2) of brake lining hammer heads/brake caliper housing and coat with anti-squeak compound.

Note. Grease contact surfaces on brake caliper at top and bottom.

Scheme 23

Clean mounting face (3) of brake caliper and apply a thin coating of anti-squeak compound.

Scheme 24

Clean brake caliper holder at hammerhead guides and apply a thin coating of anti-squeak compound.

Scheme 25

34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS (S85)

Necessary preliminary tasks

1. Remove wheels.
2. If necessary, «remove and clean brake pads»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-11-000-removing-and-installingreplacing) .

After completing work, read and comply with notes on breaking in new brake discs / brake pads .

Unfasten screws (1), remove brake caliper and fasten up.

Note. Brake hose remains connected. If the brake hose was pulled from the mounting fixture during removal, make sure it is positively attached when installed!

Installation

Tighten to specified torque. See 34 11 2AZ .

Scheme 26

Release screws (1) and remove brake disc (2).

Installation

Thoroughly clean contact surface of brake disc on wheel hub and guide pins (3), remove traces of corrosion if necessary.

Brake disc can only be mounted in one position.

Scheme 27

Replace screws.

Tighten to specified torque. See 34 11 1AZ .

34 11 250 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD PLATE AT FRONT

Necessary preliminary tasks

1. Remove «front brake disks»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-11-220-removing-and-installingreplacing) .

Release screws (1) and remove brake guard plate (2).

Installation

Tighten to specified torque. See 34 11 5AZ .

Scheme 28

34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FRONT BRAKE CALIPER

Necessary preliminary tasks

1. Remove wheels.

Observe safety instructions on raising the vehicle. See 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM .

After completing tasks, bleed brake system .

Apply pedal prop and depress brake pedal slightly. This prevents brake fluid from emerging from the expansion tank and air from entering the brake system after the brake lines have been detached.

Scheme 29

Left side: Disconnect plug connection for wear indicator.

Release brake hose on brake caliper.

Slacken connection for brake hose and brake line.

Installation

Tighten brake hose on brake caliper.

Tighten to specified torque. See 34 32 4AZ. .

Move steering to straight-ahead position.

Screw brake hose to brake line, ensuring that brake hose is not twisted.

Tighten to specified torque. See 34 32 1AZ .

Unscrew bolts (1) and remove brake caliper.

Installation

Tighten to specified torque. See 34 11 2AZ .

Scheme 30

Scheme 31

34 21 200 REMOVING AND INSTALLING OR REPLACING BRAKE LININGS ON BOTH REAR DISC BRAKES

Special tools required

1. 34 1 050
2. 34 1 080
3. 34 1 280

Necessary preliminary tasks

1. Remove wheels.
2. Remove «brake pad wear sensor»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-35-001-replacing-a-brake) .

Observe safety instructions on raising the vehicle. See 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM .

If necessary, when replacing linings, reset CBS display in accordance with factory specification.

Note. After completing work: Fully depress brake pedal several times so that brake linings contact brake discs. When installing new brake linings at front and rear axles, brake fluid level must be brought up to "MAX" marking. Read and comply with notes on breaking in new brake discs/ brake pads.

Remove plastic plugs (1).

Right side

Disconnect plug connection for brake lining wear sensor.

If necessary, replace brake lining wear sensor.

Scheme 32

Release guide screws (2) with special tool 34 1 080.

Installation

Only clean guide screws; do not grease.

Check threads.

Replace all guide screws which are not in perfect condition.

Scheme 33

Lift out retaining spring (3).

Withdraw brake caliper backwards.

Scheme 34

Turn piston fully back with special tool 34 1 050.

Scheme 35

Remove outer brake lining.

Inner brake lining is located with its spring in the piston.

If the brake linings are worn on one side, they must not be mixed up!

Observe minimum thickness of brake linings.

Clean brake linings.

Do not apply grease to brake pad backplate.

Scheme 36

Check minimum brake disc thickness

1. Position special tool 34 1 280 at three measuring points in area (1) and measure.
2. Compare measurement result and lowest value with setpoint value.

New brake linings may only be installed if the brake disc thickness is greater than or equal to the minimum brake disc thickness (MIN TH).

Check dust sleeve (1) for damage and replace if necessary.

Clean contact face (2) of brake piston and apply a thin coating of anti-squeak compound.

Check dust boot (1) for damage and replace if necessary. Clean contact surface (2) of brake piston with brake cleaner and apply a thin coating of brake pad paste.

Scheme 37

Clean mounting faces (1) and (2) of brake lining hammer heads/brake caliper housing and coat with anti-squeak compound.

Clean contact face (3) of brake caliper and apply a thin coating of anti-squeak compound.

Clean brake caliper mounting bracket at hammer head guides and apply a thin coating of anti-squeak compound.

34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH REAR BRAKE DISCS (S85)

Necessary preliminary tasks

1. Remove wheels.
2. If necessary, «remove and clean brake pads»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-21-200-removing-and-installing) .

After completing work

1. Adjust «handbrake»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-10-014-adjusting-handbrake) .
2. Read and comply with notes on «breaking in new brake discs / brake pads»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information-on-breaking) .

Release screws (1), remove brake caliper and tie up.

Note. Brake hose remains connected.

Installation

Tightening torque 34 21 3AZ .

Scheme 38

Release screws (1) and remove brake disc (2).

Installation

Make sure contact surfaces between wheel hub and brake disc are absolutely clean.

Replace screws.

Tighten to specified torque 34 21 1AZ .

Scheme 39

34 21 171 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD AT REAR

Necessary preliminary tasks

1. Remove «expander lock»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-41-250-removing-and-installingreplacing) .
2. Remove wheel hub.

Release screws (1) and remove brake carrier (2).

Installation

Tighten to specified torque 34 21 6AZ. .

Scheme 40

34 21 745 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT REAR BRAKE CALIPER

Necessary preliminary tasks

1. Remove wheels

Observe safety instructions on raising the vehicle. See 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM .

After completing tasks, bleed brake system .

Apply pedal prop and depress brake pedal slightly. This prevents brake fluid from emerging from the expansion tank and air from entering the brake system when the brake lines are opened.

Right side: Disconnect plug connection for brake lining wear sensor.

Unfasten screws (1).

Installation: Tightening torque 34 21 3AZ .

Installation

Release brake hose (2).

Installation: Tightening torque 34 32 5AZ .

Unfasten brake hose at connection point to brake line.

Installation: Tightening torque 34 32 1AZ .

First tighten the brake hose on the brake cover, then tighten connection on brake line.

Install brake hose without torsional stress.

Pull off fist caliper towards rear of vehicle.

Scheme 41

Scheme 42

34 31 181 REMOVING AND INSTALLING / REPLACING EXPANSION TANK FOR HYDRAULIC BRAKE ACTUATION

Necessary preliminary tasks

1. Remove lower section of microfilter housing. See «64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION»(ref-379401-S13162676242010121300000) .
2. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .

Suck the brake fluid out of the expansion tank. Use suction bottle exclusively to draw off brake fluid.

Scheme 43

Unfasten plug connection (1) and disconnect.

Release retaining screw (2).

Installation

Tighten to specified torque 34 31 3AZ .

Pull expansion tank vertically out of brake master cylinder.

Scheme 44

Check rubber plug in brake master cylinder for damage and replace if necessary.

Push the expansion tank vertically onto the master brake cylinder.

Scheme 45

34 31 505 REMOVING AND INSTALLING / REPLACING MASTER BRAKE CYLINDER FOR DSC

Special tools required

1. 32 1 270

Necessary preliminary tasks

1. Remove «expansion tank»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-31-181-removing-and-installing) .
2. Remove footwell trim. See «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .
3. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .

After completing tasks, bleed brake system with DSC .

Remove locking clip (1) and disengage and pull out locking pin.

Slacken nuts (2).

Installation

Replace self-locking nuts.

Tighten to 21 Nm.

Scheme 46

Unfasten brake lines (1).

Detach brake lines at junction (2) and remove short sections.

Seal off brake lines and brake master cylinder with plugs 32 1 270.

Installation

Fit lines at both connection points and then tighten down.

Tighten to specified torque. See 34 32 1AZ.

Release nuts (3) and feed brake master cylinder out of brake booster.

Scheme 47

Installation

Replace self-locking nuts.

Tighten to specified torque. See 34 31 1AZ .

Installation

Replace sealing ring.

Scheme 48

Installation

When inserting the brake master cylinder (2) into the brake booster (1), make sure the pressure rod of the brake booster and that of the brake master cylinder meet each other on one level.

Scheme 49

Scheme 50

34 32 861 REPLACING ALL BRAKE PIPES

Special tools required

1. 34 5 100

Note. The brake lines are only supplied in the straight version and correct length with connecting nipple. Read and comply with General Information . After completing work, bleed brake system .

Observe safety instructions on raising the vehicle. See 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM .

New brake lines are bent into shape with bending tool 34 5 100. Removed brake pipes can be used as templates for bending.

Installation

Tighten to specified torque. See Brake Lines .

Scheme 51

34 32 881 REPLACING FRONT LEFT OR RIGHT BRAKE HOSES

Note. After completing tasks, bleed brake system .

Apply pedal prop and depress brake pedal slightly. This prevents brake fluid from emerging from the expansion tank when the brake lines are opened.

Pull brake hose out of holder (1).

Installation

Detach brake hose from brake line (2).

Tightening torque 34 32 1AZ. .

Installation

Detach brake hose from brake caliper (4).

Tightening torque 34 32 4AZ.

Scheme 52

Installation

First tighten brake hose on brake caliper.

Move wheels into straight-ahead position.

Insert brake hose in bracket and screw onto brake pipe.

34 32 980 REPLACING REAR LEFT OR RIGHT BRAKE HOSES

Note. Read and comply with General Information . Observe safety instructions on raising the vehicle. See 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM . After completing tasks, bleed brake system . Apply pedal prop and depress brake pedal slightly. This prevents brake fluid from emerging from the expansion tank and air from entering the system when the brake lines are opened.

Disconnect brake hose from brake line (1).

Installation : Tightening torque 34 32 1AZ.

Installation

Detach brake hose from brake caliper (3).

Tighten to specified torque. See 34 32 5AZ. .

Scheme 53

34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (S85)

Necessary preliminary tasks

1. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .
2. Remove lower section of microfilter housing. See «64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION»(ref-379401-S13162676242010121300000) .

Disconnect plug connection (1).

Unscrew nuts (2).

Unlock quick-release fastener (3) and detach vacuum hose.

Scheme 54

Release clamp (1) and detach vacuum line.

Installation

Replace clamp (1).

Detach non-return valve (2) from brake booster and remove vacuum line (3).

Installation

Check sealing ring in brake booster and replace if necessary.

Scheme 55

When replacing vacuum line

Release screws (1) and convert differential pressure switch (2).

Scheme 56

34 33 075 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (S85)

Necessary preliminary tasks

1. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information)
2. Remove lower section of microfilter housing. See «64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION»(ref-379401-S13162676242010121300000) .

Disconnect plug connection (1).

Unlock quick-release fastener (2) and detach vacuum hose.

Release nuts (3) and remove vacuum pump.

Scheme 57

34 33 505 REMOVING AND INSTALLING/REPLACING BRAKE BOOSTER

Necessary preliminary tasks

1. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .
2. Remove «brake master cylinder»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-31-505-removing-and-installing) .

For cars with S85 engines

1. Remove «vacuum pump»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-33-075-removing-and-installingreplacing) .
2. Remove bracket for vacuum pump.
3. Remove «vacuum line»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-33-071-replacing-vacuum-hose) .

Detach locking clip (1) from brake pedal, disengage and pull out locking pin.

Unscrew nuts (2).

Installation

Replace self-locking nuts.

Tighten to specified torque. See BRAKE BOOSTER .

Remove non-return valve (1) from brake booster.

Carefully pull brake booster (2) out of bulkhead and tilt out.

Installation

Replace seal between brake booster and bulkhead.

Scheme 58

34 35 001 REPLACING A BRAKE LINING SENSOR

Necessary preliminary tasks

1. Remove wheel

Open cover (1) on plug housing (3).

Unclip lead of brake lining sensor (2) from plug housing (3).

Disconnect associated plug connection of lead from brake lining sensor (2).

Feed lead from brake lining sensor (2) out of fixtures.

Scheme 59

Press clip (1) together and detach brake lining sensor (2) in direction of arrow from brake caliper (3).

Installation

Make sure clip (1) and brake lining sensor (2) are correctly seated in brake caliper (3).

Scheme 60

34 10 014 ADJUSTING HANDBRAKE

Special tools required

1. 32 1 030

Perform inspection in the following manner

When 1st ratchet is engaged, no braking force should be exerted.

The difference in wheel circumferential forces between the left and right wheels may deviate by max. 30 % from the greater value (measured on brake analyzer).

In event of larger deviations of wheel circumferential force: carry out readjustment.

It must be possible to brake with locked wheels with the handbrake.

The handbrake must be readjusted whenever the actuation stroke is greater than 10 teeth.

Note. The handbrake can only be adjusted correctly when the parking brake Bowden cables and all moving handbrake parts are free to move and fully operational.

Basic handbrake adjustment is necessary

1. When replacing parking brake shoes.
2. When replacing brake disks.
3. In event of excessive actuation stroke (10 teeth).
4. When replacing parking brake Bowden cables

Scheme 61

Scheme 62

Scheme 63

Scheme 64

1. Setting instruction for brake shoes (basic setting) Lock adjuster unit (ASZE). Using special tool 32 1 030, press stop (1) of adjusting spring back to such an extent that retaining hook (2) engages in stop (1). Completely unscrew one wheel stud on each rear wheel. Installation: Tighten to specified torque. 130-110 Nm. Turn wheel until adjustment screw is visible in tapped hole. Turn adjusting screw with a screwdriver until the wheel is no longer able to turn. Then unfasten the adjusting screw 8 notches. Unlock adjuster unit (ASZE). Lever restraint hook (2) outwards with a suitable screwdriver (1). Restraint hook (2) must disengage from stop of adjusting spring.
2. Setting instruction for parking brake Bowden cables The handbrake lever must be applied 5 times to approx. 400N actuating force. 2.1 On brake analyzer 0th tooth (handbrake released): Vehicles with manual transmission: Shift lever in neutral position Vehicles with automatic transmission: Selector lever in N position. Without locking differential < or = 150 N. With locking differential < or = 200 N (possibly odd display). 1st tooth: No increase in braking force with regard to 0th tooth. Indicator lamp can be lit. 2nd tooth: Indicator lamp must be lit. 3rd tooth: Increase in braking force. 5th tooth: The brake force display must have reached > or = tooth: 400 N. Checking brake force differential at wheel: Apply handbrake until a wheel circumferential force (brake force display) of min. 1000 N is reached. Max. permitted brake force differential right/left < or = 35 % (referred to greater brake value).
3. Breaking in the duo-servo parking brake The following breaking-in procedures are applicable in case of insufficient braking effect or after replacing brake disks and/or brake shoes. On brake analyzer Apply handbrake lever until wheel circumferential force on first wheel is 800 N. Lock lever in next lower tooth. Release handbrake lever after approx. 2 minutes. When driving on road (If possible inside the company grounds or on an unused road) At approx. 40 km/h, apply handbrake lever until braking action can be felt. Pull up handbrake lever into next notch and drive on for approx. 400 m. A basic requirement is that handbrake is adjusted uniformly.

Note. If necessary, repeat breaking-in procedure.

Scheme 65

34 41 000 REMOVING AND INSTALLING / REPLACING HANDBRAKE LEVER

Special tools required

1. 32 1 030

Necessary preliminary tasks

1. Remove center console

After completing tasks, adjust handbrake.

Lock adjuster unit (ASZE).

Using special tool 32 1 030, press stop (2) of adjusting spring back to such an extent that retaining hook (3) engages in stop (2).

Unclip mounting clip (1) upwards out of balance arm (2).

Scheme 66

Guide handbrake Bowden cables (1) with a screwdriver inwards and pull out of balance bar (2).

Scheme 67

Disconnect cable (1) from handbrake check switch.

Release screws (2) and remove handbrake lever (3).

Installation

Tighten to specified torque. See PARKING BRAKE .

Handbrake lever and adjustment unit (ASZE) are only exchanged completely as a single unit.

Scheme 68

34 41 120 REMOVING AND INSTALLING / REPLACING BOTH HANDBRAKE BOWDEN CABLES

Special tools required

1. 32 1 030

Necessary preliminary tasks

1. Remove center console. See «51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-200-removing-and-installing) .
2. Remove «rear brake disks»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-21-320-removing-and-installing)
3. Remove exhaust system.
4. Remove heat shield.

After completing tasks, adjust handbrake .

Lock adjuster unit (ASZE).

Using special tool 32 1 030, press stop (1) of adjusting spring back to such an extent that retaining hook (2) engages in stop (1).

Unclip mounting clip (1) upwards out of balance arm (2).

Guide handbrake Bowden cables (1) with a screwdriver inwards and pull out of balance bar (2).

Disconnect handbrake Bowden cables at expander locks.

Release screw (1) and remove bracket.

Installation

Tighten to specified torque. See 34 41 5AZ.

Pull handbrake Bowden cables (2) out of wheel carrier.

Scheme 69

Disconnect handbrake Bowden cables (1) out of mountings.

Pull handbrake Bowden cables (1) out of guide (2) and remove.

Scheme 70

34 41 220 REMOVING AND INSTALLING/REPLACING ALL HANDBRAKE SHOES

Special tools required

1. 32 1 030
2. 34 4 000

Necessary preliminary tasks

1. Remove «rear brake disk»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-21-320-removing-and-installing)

After completing work

1. Adjusting handbrake

Release handbrake lever.

Lock adjuster unit (ASZE).

Using special tool 32 1 030, press stop (1) of adjusting spring back to such an extent that retaining hook (2) engages in stop (1).

Disconnect return spring (1) with brake spring pliers.

Installation

Check and if necessary replace return spring (1).

Pay attention to installation position of adjustment screw (2).

Apply a thin coat of grease to bush and screw threads.

Scheme 71

Disconnect return spring (1) with brake spring pliers.

Installation

Check and if necessary replace return spring (1).

Scheme 72

Turn clamping pins (1) with special tool 34 4 000 through 90° and disconnect.

Remove brake shoes (2).

Scheme 73

34 41 250 REMOVING AND INSTALLING/REPLACING EXPANDER LOCK FOR HANDBRAKE SHOES

Special tools required

1. 32 1 030

Necessary preliminary tasks

1. Remove «handbrake shoes»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-41-220-removing-and-installingreplacing) .

After completing work

1. Adjust handbrake.

Lock adjuster unit (ASZE).

Using special tool 32 1 030, press stop (1) of adjusting spring back to such an extent that retaining hook (2) engages in stop (1).

Pull expander lock (1) forwards, disconnect handbrake Bowden cable (2) and remove expander lock.

Scheme 74

34 51 527 REMOVING AND INSTALLING/REPLACING HYDRAULIC UNIT FOR DSC (S85)

Necessary preliminary tasks

1. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .
2. Remove «FRONT LEFT WHEEL ARCH COVER»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-71-040-removing-and-installingreplacing) .
3. Remove front left support.

After completing tasks, bleed brake system .

Installation

After reinstalling the hydraulic unit, carry out the following tasks with the DIS (Diagnosis and Information System)

1. Mix-up check of brake lines
2. Function check, hydraulic unit

Apply pedal prop and depress brake pedal slightly. This prevents brake fluid from emerging from the expansion tank and air from entering the brake system after the brake lines have been detached.

Unfasten plug connection (1).

Unfasten brake lines (2).

Installation

Tighten to specified torque. See SLIP CONTROL SYSTEM .

Release bolts (3) and remove hydraulic unit.

Scheme 75

When replacing hydraulic unit

1. Release bolts (1) and modify bracket (2).
2. Modify control unit

Scheme 76

Necessary preliminary tasks

1. Remove wheel

Open cover (1) on plug housing (3).

Unclip lead of brake lining sensor (2) from plug housing (3).

Disconnect associated plug connection of lead from brake lining sensor (2).

Feed lead from brake lining sensor (2) out of fixtures.

Press clip (1) together and detach brake lining sensor (2) in direction of arrow from brake caliper (3).

Installation

Make sure clip (1) and brake lining sensor (2) are correctly seated in brake caliper (3).

Scheme 77

34 52 516 REMOVING AND INSTALLING/REPLACING DSC CONTROL UNIT (S85)

Necessary preliminary tasks

1. Remove «hydraulic unit»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-51-527-removing-and-installingreplacing) .

When replacing control unit

1. Carry out programming/coding
2. Adjustment of steering angle sensor
3. Mix-up check of brake lines
4. Function check, hydraulic unit

Release screws (1) and carefully detach control unit (2) towards front.

Scheme 78

Installation

Keep sealing faces clean.

Replace screws.

Observe tightening sequence (1-4).

Tighten to specified torque. See SLIP CONTROL SYSTEM .

Scheme 79

34 52 525 REPLACING ONE FRONT PULSE GENERATOR

Note. Read and comply with General Information . Observe safety instructions on raising the vehicle. See 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM .

Open plug housing (1), pull plug connection (2) out of bracket and disconnect.

Pull cable with rubber grommet out of bracket on spring strut.

Installation

Ensure proper locking of plug connector and proper seating of rubber grommets.

Scheme 80

Release hexagon socket head cap screw (1) and pull wheel speed sensor out of bore.

Installation

Tighten to specified torque. See 34 51 6AZ. .

Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease.

Scheme 81

34 52 535 REPLACING A REAR PULSE GENERATOR

Necessary preliminary tasks

1. Remove rear wheel.
2. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .

Observe safety instructions on raising the vehicle. See 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM .

Open plug housing (1).

Pull plug connection (2) out of mounting and disconnect.

Pull cable out of brackets on swinging arm.

Installation

Ensure proper locking of the plug connector and proper seating of the cable in the brackets.

Scheme 82

Release hexagon socket head cap screw (1) and pull wheel speed sensor out of bore.

Installation

Tighten to specified torque. See 34 51 6AZ.

Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease.

Scheme 83

34 52 550 REMOVING AND INSTALLING/REPLACING DSC SENSOR (S85)

Necessary preliminary tasks

1. Remove right front seat. See «SEATS»(/bmw/m5/e60e61-2004-2010/remont/seats/#seats-repair-instructions) .
2. Remove front inside entrance cover strip. See «51 47 000 REMOVING AND INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT ENTRANCE COVER STRIP»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-000-removing-and-installingreplacing) .

Lift carpet (1) and fold to side.

Release screws (2) and swing out DSC sensor (3).

Installation: Tightening torque 34 51 3AZ .

Scheme 84

Unlock plug connection (1) and remove DSC sensor (2).

Installation

Make sure plug connection locks correctly.

Scheme 85

34 52 575 REMOVING AND INSTALLING/REPLACING FRONT PRESSURE SENSOR FOR ACC

Necessary preliminary tasks

1. Remove front right wheel arch trim. See «51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH COVER»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-71-040-removing-and-installingreplacing) .
2. Read and comply with «General Information»(/bmw/m5/e60e61-2004-2010/remont/mechanical-hydraulic/#brakes-repair__34-00-general-information) .

After completing tasks, bleed brake system .

Apply pedal prop and depress brake pedal slightly. This prevents brake fluid from emerging from the expansion tank and air from entering the brake system after the brake lines have been detached.

Unfasten plug connection (1).

Release pressure sensor (2) and remove.

Installation

Tighten to specified torque. See 34 51 12AZ. .

Scheme 86

34 52 580 REMOVING AND INSTALLING / REPLACING REAR PRESSURE SENSOR FOR ACC

Note. Read and comply with General Information .

After completing tasks, bleed brake system .

Apply pedal prop and depress brake pedal slightly. This prevents brake fluid from emerging from the expansion tank and air from entering the brake system after the brake lines have been detached.

Vehicles with N52 engine

If necessary, remove heat shield (1).

Installation

Make sure heat shield is correctly seated.

If necessary, replace heat shield.

Scheme 87

Disconnect plug connection (1).

Release pressure sensor (2) and remove.

Installation

Tighten to specified torque. See 34 51 12AZ.

Scheme 88

See also:
• BRAKES - OPERATING FLUIDS
• BRAKES - TECHNICAL DATA
• 34 32 1AZ.
• 00...... LIFTING VEHICLE WITH A LIFTING PLATFORM
• 34 11 2AZ
• 34 21 3AZ
• 34 31 3AZ
• 51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY
• BRAKE BOOSTER
• PARKING BRAKE
• 51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT
• FRONT LEFT WHEEL ARCH COVER
• SLIP CONTROL SYSTEM
• 61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE)
• SEATS
• 51 47 000 REMOVING AND INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT ENTRANCE COVER STRIP
• 34 51 3AZ
• General Information
• brake pad wear sensor
• remove and clean brake pads
• breaking in new brake discs / brake pads
• front brake disks
• bleed brake system
• remove and clean brake pads
• handbrake
• expander lock
• expansion tank
• bleed brake system with DSC
• brake master cylinder
• vacuum pump
• vacuum line
• rear brake disks
• handbrake shoes
• hydraulic unit