Benji
Well-known member
With some time off work over the festive season, I stocked the fridge and roped some friends in to help me finish the 540i...we got pretty darn close 😎
After countless hours of mind numbing wet-sanding and polishing of paintwork, I shifted focus to the fun stuff - mechanicals.
I replaced the gearbox detent pins, lock pins and oil seals. It was a bit nerve wracking at first, but I took my time and enjoyed the process. The old style detent is a ball and spring vs later one with a rounded sleeve and spring.
Note the beefy Z4 speaker which acted as the magnet to remove the balls and pins
Remove the flywheel to reveal a pathetically weeping rear main seal. Did the right thing and replaced the rear coolant cover while I was in the postal code.
Of course the original clutch was a bit tired
Installed a new LUK clutch that came in a Sachs box and stamped with both brands - weird, but a nice surprise! New release bearing, clutch pivot pin and fluid flush.
Onto my continued obsession with diffs...from left to right, E39 540i (2.81 open), E39 M5 (3.15 LSD) and E32/E34 (3.15 open).
The M5 diff bolts into the 540i provided you use the E32/E34 output flanges and the M5 propshaft. Note how the M5 diff is the same as the E34 diff, just the front mount is a bit different. Slapped it all in with the customary new centre support bearing and guibo. I also installed the M5 rear stabilizer bar to compliment the LSD and tighten up the handling a bit.
A quick spot of cleaning:
After:
Engage my finest use of zulu, afrikaans and german fowl language to replace the complete suspension. Also, honorable mention to the sadistic dimwit who designed the rear shock mounts access which necessitate removing the whole rear interior as well as the subwoofer! I'm sure he (she?) is the same nitwit who designed the E34 cabin air filter.
Out with the old:
In with Bilstein B6 with new everything including dust cover and spring mounts. Note how much more spring travel the Bilsteins allow...weird.
New discs, pads, wear sensors and handbrake shoes
Lovely
Gave the wheels a little detail and seal:
One last check for oil leaks before buttoning everything up:
New gearknob and M5/Individual wood trim for the handbrake
A fantastically awesome waste of money, you'd agree!
Speaking of wasting money...M5 wing mirrors:
The last few touches:
Sneak peak of the first time this car has had its front spoiler on...getting exciting now!
Had to re-plug a few of the headlight plugs which had broken clips, about R50 per plug, but pretty easy to do
New Willard battery and first start in months 😎
First drive
Did the wheel alignment and sorted out a few niggles. Immidiately got the car dirty by driving in the rain and "stress testing" it on the quiet highways...this car pulls like an absolute train with the M5 diff which effectively gives me 10% more power at all times. It was still pulling strong at twice the national speed limit. The motor sits at 2500rpm at 120kph, still a very relaxed cruising speed for the V8. The wet roads afforded plenty opportunity to test the LSD...it works The stiffer rear anti-roll bar has also tightened up the handling, the car feels a bit more eager to turn in - but that could also be the WHOLENEW SUSPENSION lol
Still one of the best BMW designs...
What an absolute unit of a car! I had almost forgotten why I was doing all this work. At times it felt like a chore. When painters were involved, it felt like I was paying karmic debt. But with the support, encouragement and assistance of friends and some forum members, the car is finally done! It only took me 3 years 👀
Well...almost. The AC has decided it doesnt work anymore, I need to buy new bumper trims, install new front and rear windscreen trims, tint the windows, install the boot spoiler and give the car a final polish and detail. But for now, I am dailying this car and enjoying the sweet fruit of my labour.
Many, many thanks to my long-suffering bank account, my quick healing hands, my stubborn determination, my patient and sometimes understanding SO, friends who provided encouragement, friends who provided labour and assistance and lastly, the BMW community who assisted in many ways.
Cheers for reading, here is to a fantastic new year of enjoying your cars! 🍻
After countless hours of mind numbing wet-sanding and polishing of paintwork, I shifted focus to the fun stuff - mechanicals.
I replaced the gearbox detent pins, lock pins and oil seals. It was a bit nerve wracking at first, but I took my time and enjoyed the process. The old style detent is a ball and spring vs later one with a rounded sleeve and spring.
Note the beefy Z4 speaker which acted as the magnet to remove the balls and pins
Remove the flywheel to reveal a pathetically weeping rear main seal. Did the right thing and replaced the rear coolant cover while I was in the postal code.
Of course the original clutch was a bit tired
Installed a new LUK clutch that came in a Sachs box and stamped with both brands - weird, but a nice surprise! New release bearing, clutch pivot pin and fluid flush.
Onto my continued obsession with diffs...from left to right, E39 540i (2.81 open), E39 M5 (3.15 LSD) and E32/E34 (3.15 open).
The M5 diff bolts into the 540i provided you use the E32/E34 output flanges and the M5 propshaft. Note how the M5 diff is the same as the E34 diff, just the front mount is a bit different. Slapped it all in with the customary new centre support bearing and guibo. I also installed the M5 rear stabilizer bar to compliment the LSD and tighten up the handling a bit.
A quick spot of cleaning:
After:
Engage my finest use of zulu, afrikaans and german fowl language to replace the complete suspension. Also, honorable mention to the sadistic dimwit who designed the rear shock mounts access which necessitate removing the whole rear interior as well as the subwoofer! I'm sure he (she?) is the same nitwit who designed the E34 cabin air filter.
Out with the old:
In with Bilstein B6 with new everything including dust cover and spring mounts. Note how much more spring travel the Bilsteins allow...weird.
New discs, pads, wear sensors and handbrake shoes
Lovely
Gave the wheels a little detail and seal:
One last check for oil leaks before buttoning everything up:
New gearknob and M5/Individual wood trim for the handbrake
A fantastically awesome waste of money, you'd agree!
Speaking of wasting money...M5 wing mirrors:
The last few touches:
Sneak peak of the first time this car has had its front spoiler on...getting exciting now!
Had to re-plug a few of the headlight plugs which had broken clips, about R50 per plug, but pretty easy to do
New Willard battery and first start in months 😎
First drive
Did the wheel alignment and sorted out a few niggles. Immidiately got the car dirty by driving in the rain and "stress testing" it on the quiet highways...this car pulls like an absolute train with the M5 diff which effectively gives me 10% more power at all times. It was still pulling strong at twice the national speed limit. The motor sits at 2500rpm at 120kph, still a very relaxed cruising speed for the V8. The wet roads afforded plenty opportunity to test the LSD...it works
The stiffer rear anti-roll bar has also tightened up the handling, the car feels a bit more eager to turn in - but that could also be the WHOLENEW SUSPENSION lolStill one of the best BMW designs...
What an absolute unit of a car! I had almost forgotten why I was doing all this work. At times it felt like a chore. When painters were involved, it felt like I was paying karmic debt. But with the support, encouragement and assistance of friends and some forum members, the car is finally done! It only took me 3 years 👀
Well...almost. The AC has decided it doesnt work anymore, I need to buy new bumper trims, install new front and rear windscreen trims, tint the windows, install the boot spoiler and give the car a final polish and detail. But for now, I am dailying this car and enjoying the sweet fruit of my labour.
Many, many thanks to my long-suffering bank account, my quick healing hands, my stubborn determination, my patient and sometimes understanding SO, friends who provided encouragement, friends who provided labour and assistance and lastly, the BMW community who assisted in many ways.
Cheers for reading, here is to a fantastic new year of enjoying your cars! 🍻
