Download BMW 5 Series (E39) 540i Sedan 1997-2002Service Manual –

Ah, the BMW E39 540i – a truly magnificent piece of engineering! View and download the manual with one click here……

When it comes to the suspension system, the suspension arm plays a pivotal role in ensuring that your vehicle handles well and provides a smooth ride. Now, let’s delve into the detailed process of replacing a suspension arm on this fine machine. Buckle up, because it’s going to be a thorough ride!

### Tools and materials Needed

Before we get into the nitty-gritty of the repair, let’s talk about the tools and materials you’ll need:

1. **Jack and Jack Stands**: A hydraulic floor jack is essential for lifting the vehicle safely. Pair it with jack stands to securely support the car once it’s elevated.

2. **Lug Wrench**: This tool will help you remove the lug nuts from the wheels. A cross wrench or a breaker bar can provide adequate leverage, especially if the nuts are stubborn.

3. **Socket Set**: A comprehensive socket set is critical. You’ll need both metric and imperial sizes, but for the E39, you’re mostly looking at 16mm, 18mm, and 21mm sockets.

4. **Torque Wrench**: This tool ensures that when you reassemble components, you can apply the correct amount of torque specified by BMW to prevent any issues down the line.

5. **Pry Bar**: Useful for separating components that may be stuck together. It provides leverage to help dislodge parts without causing damage.

6. **Ball Joint Separator**: This specialized tool is designed to separate the ball joint from the suspension arm without causing damage to the joint or the arm itself.

7. **Hammer**: Sometimes, a little persuasion is needed. A rubber mallet is preferable as it minimizes damage, but a standard hammer can also work.

8. **Wrenches**: A set of open-end and box-end wrenches, especially in metric sizes, will come in handy for stubborn bolts.

9. **Grease and Grease Gun**: If your new suspension arm has grease fittings, you’ll want to ensure they’re well-lubricated upon installation.

10. **Replacement Suspension Arm**: Make sure you have the correct part. It’s wise to consult your vehicle’s VIN or refer to the specific parts catalog for the E39.

### Step-by-Step Process

#### 1. Preparation

First and foremost, ensure you’re working in a safe environment. Park the car on a flat surface and engage the parking brake. It’s also a good idea to work on a surface that allows for easy access to the underside of the vehicle.

#### 2. Lifting the Vehicle

Using the hydraulic jack, lift the front of the car. Place jack stands under the designated jack points to secure the vehicle. Always ensure that the vehicle is stable before proceeding with any work underneath.

#### 3. Removing the Wheel

Using the lug wrench, loosen the lug nuts on the wheel that corresponds to the suspension arm you’re working on. Once loosened, remove the nuts entirely and take the wheel off. This gives you better access to the suspension components.

#### 4. Inspecting the Suspension Arm

Before diving into the removal, take a moment to inspect the existing suspension arm. Look for any signs of wear, such as cracks, excessive rust, or play in the joints. This will give you a clearer picture of what you’re replacing.

#### 5. Removing the Old Suspension Arm

Locate the mounting points of the suspension arm. Typically, there are two or three bolts that secure it to the chassis and the hub.

– **Loosen the Bolts**: Start by using your socket set to loosen and remove the bolts. you may need to use penetrating oil if they’re particularly rusted. Allow the oil to soak in for a few minutes for easier removal.

– **Separating the Ball Joint**: If the arm is connected to a ball joint, use the ball joint separator to carefully separate it. Position the separator at the joint download BMW 5 E39 540i Sedan workshop manual and tighten the tool until the joint pops free. Be cautious and don’t apply too much force, as this can damage the components.

– **Remove the Arm**: Once all bolts and joints are disconnected, carefully maneuver the old suspension arm out of place. you might need to use a pry bar to assist in separating it from any other attached components.

#### 6. Installing the New Suspension Arm

Now that the old arm is out, it’s time to install the new one.

– **Position the New Arm**: Align the new suspension arm with the mounting points. Make sure it fits snugly into position without forcing it.

– **Secure the Bolts**: Hand-tighten the bolts first to ensure everything is aligned correctly. Once you’re satisfied with the positioning, use the socket set to tighten the bolts to the manufacturer’s specifications. This is where your torque wrench comes into play. Each bolt will have a specific torque value, which can be found in the service manual.

– **Reattach the Ball Joint**: If applicable, fit the ball joint back into place. If it requires a cotter pin, make sure to install it according to specifications.

#### 7. Reassembly

Once everything is securely fastened, it’s time to reattach the wheel. Position the wheel back onto the hub and hand-tighten the lug nuts. Lower the vehicle back down to the ground using the hydraulic jack and then fully tighten the lug nuts in a crisscross pattern to ensure even pressure.

#### 8. Final Checks

Before taking your BMW for a spin, double-check all connections and bolts to ensure everything is secure. It’s also advisable to take the car for a short drive and listen for any unusual noises, which could indicate something was not installed correctly.

### Conclusion

And there you have it! You’ve successfully replaced the suspension arm on a BMW E39 540i Sedan. Remember, working on suspension components is critical for vehicle safety and performance, so if you ever feel unsure, don’t hesitate to consult a professional mechanic. Happy driving, and may your E39 handle beautifully on the road!
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