Bolt Extractor to Remove Stripped Transmission Support Bolt on BMW E39

I broke a support brace bolt, while replacing my old transmission mounts on the E39. The bolt was broken at the head, and the threaded shank was left in the hole. I heard it snap and felt sick to my stomach. It was the last bolt to be removed to the brace and I didn't know what to do.

I looked online and apparently, breaking transmission support brace bolts is common. They are exposed to road salt, and get rusted out. Drive train components last for years before maintenance, so these bolts don't get taken out often.

The solution:

• Extract the broken bolt with a screw extractor. 
• If extraction doesn't work, drill it out. 
• Rethread with tap and die, if female threads are stripped
• Helicoil, if cutting threads doesn't work with tap and die

Broken bolt and stuck screw

I purchased the Werkzeug damaged and stripped screw extractor set and a  a Gearwrench Ratcheting Tap and Die set as well. There are 22 pieces and it comes with an magnetic extension bit holder and socket adapter.

I placed the bit holder in my drill, and picked the smallest driller. I started drilling, and had some difficulty establishing a clean hole to use the bit. I lowered the drill speed and alternated between driller sizes. I was really skeptical at first, because the bits are so small. I questioned myself, if I was doing this right at all, and if this would even work. I pressed on, out of desperation.

After 25 minutes of drilling, I finally got a good clean hole and put in the extractor. I pressed the trigger and could see the screw turning a little but it stopped. So more drilling, with a larger driller. I stepped up the extractor to #6 and the broken screw finally came out. I was elated and so happy.

Broken screw with extractor tool

Broken screw removed

I cleaned up the threads with a tap and die, removed and replaced the old transmission mounts, and put in a new support bolt into the brace.

The $20 extractor kit saved me a trip to the shop. Every do-it-yourself mechanic needs to have one of these. It is such a lifesaver, especially in tight spots where cutting the bolt is not feasible.

E39 Trunk Release Button Does Not Work

My E39 trunk button would not work but the key fob would unlock the trunk. This is because the lock on the trunk is in Valet mode. To get out of valet mode, stick your key into the trunk lock and make sure you it's in the vertical position.

I thought this was an electronic issue at first and didn't think much of it. Just a slight annoyance that I had to use the key fob to unlock the trunk. I figured it would be very expensive to fix so I didn't mind. This became an issue when I had to turn of the car and use the key fob for the trunk. I looked online and found other owners having this issue.

EMP Stewart Water Pump

Comparison of EMP Stewart water pump and OEM on E39 530i.

The EMP Stewart water pump is a high performance all metal pump that comes with lifetime warranty. They claim 20% increased water flow over OEM which works well with larger pulleys for maximum performance.

I have been using the EMP Stewart water pump for over 10K miles and hope to get many more miles. It's not cheap at $175 - $195, but the benefits outweigh the costs.

Used on my M54B30 engine and will fit any related engines.

High quality construction and looks great

Beefier than OEM and larger impeller

Installation is the same as OEM. I highly suggest buying an aftermarket aluminum pulley instead of using the OEM plastic one. Since you have removed everything to get to the water pump, replace the pulley to prevent it from cracking over time.

This pump is a E36 M3 favorite with lower drag and more efficient cooling. Many E36 M3 drivers in my BMWCCA club swear by this pump on their tracking days.

Zimmerman Z-Coated Rear Rotor on E39 530i

Zimmerman Z-Coated rear rotor and StopTech street performance brake pads on a BMW E39 530i. H&R sport springs and Bilstein sport shocks shown as well.

Braking performance is amazing and I love this setup. Only downside is the amount of dust the StopTech brake pads generate.

Aftermarket Cup Holder Replacement for BMW E39 5 Series

This DIY applies to all E39 5 Series 97-03.

OEM cup holders are notorious for breaking because they are extremely flimsy and there aren't any other cup holder locations. If you are lucky, the cup holder will break while open so there is access to the Phillips screws. If the cup holder is broken while closed and you cannot open then removal of the audio and climate controls may be necessary. A small flat head screwdriver may be used to pry open the flanges from the side to access the screws.

Luckily there are aftermarket options that are durable and cheap. The only downsides are they take up the tray area because there aren't flanges and accessibility to the climate control may be difficult with drinks.

I went with the FGT Motorsport E39 Front Cup Holder Upgrade which has been working great. Every aftermarket cup holder looks exactly the same and another good one is the TrunkNets E39 Premium Front Cup Holder.

I have added pictures below of what the aftermarket cup holders look like and how they attach to the tray.

If the flanges are open:
Locate screws on cup holder and remove using Phillips screwdriver.

Cup holder removed to reveal cheap flimsy plastic parts.

Cup holder removed.

Remove tape cover and attach aftermarket cup holder to tray. 

Done! Enjoy your drinks without having to holding them in between your legs. The FGT cup holders are very sturdy and I can fit large drinks in them. No more annoyance looking down at seeing broken flanges, they are replaced with a clean and classy aftermarket mod.

How to Remove & Replace E39 5 Series Windshield Wiper Relay

DIY: BMW E39 01+ 5 Series Windshield Wiper Relay

If the windshield wipers do not work or start acting weird on your 5 Series, the simplest thing you can check or change is the Windshield Wiper Relay/Switch. The relay is located under the passenger side microfilter box and easy to get to.

This DIY applies to all E39 5 Series made after 2001. I believe the procedure is the same for earlier E39 models but the relay(s) are different.

Tools: 

• 6mm hex bit socket and ratchet
• Extension (Optional)
• Dielectric Grease (Optional)
• Flat head screwdriver 

Parts: 

• BMW Multi Purpose 7-Prong Relay
• Part # 61368384505
• It is brown colored

Steps: 

• Remove passenger side microfilter box.

Driver side box is pictured. Remove the Passenger side box.

• Use a flat head screwdriver and push down on plastic tabs to disconnect air duct. (Red)
• Unclip metal latch holding air filter cover. (Purple)
• Remove air filter tray cover. (Yellow)
• Remove cabin micro filter. 
• Remove rubber trim/weather stripping around cabin filter tray. 
• Squeeze and remove metal clip from screw holding tray to body of vehicle. (Blue)
• Lift and remove cabin air tray. 

• Remove relay box cover.

• Remove four bolts (green) using 6mm hex bit socket and ratchet.
• Remove relay box cover
• There are two small plastic tabs/clips on the back of the cover that attaches to the relay box. Gently work the cover until it comes free, if the plastic is so brittle the clips may break which is okay since the cover is held by the other four bolts. 

• Remove and replace old relay.
• Relay location is circled in red.
• Simply pull out and insert the relay. There is only one way the relay can be inserted and is dummy proof. 
• Optional: Apply dielectric grease  to the relay pins to prevent corrosion or water damage. 

• Check and see if windshield wipers are operating correctly. 
• Re-installation is the opposite of removal steps. 
• Re-attach relay box cover.
• Install four 6mm hex bolts. 
• Reinstall microfilter box with rubber trim, clips, and reattach air tube.

Notes:

The relay box also contains the fuel injector, DME, Auxiliary Fan, Air Pump, ABS, and Auxiliary Fan Stage 3 relays. This DIY has the exact same steps if you need to access these relays and fuses. 

If the windshield wipers are still not operational or acting funny, it may be the wiper switch on the driving column, wiper assembly, or wiper motor that is not working. The relay is the easiest and cheapest thing to check first.

Make sure relay box cover is snug and there are no cracks so there is no water coming into the relay box.

If you don't want to spend money on a new relay, you can try cleaning the relay contacts and see if the windshield wipers work. 

DIY: Brake Fluid Flush on BMW E39 5 Series

How to change brake fluid on a BMW E39 5-Series using the Motive European Power Brake Bleeder w/ Adapter

BMW recommends flushing brake fluid every two years for everyday street driving.

Tools: 

• Flathead screwdriver
• 9 mm wrench 
•  Box end wrench may be helpful
• Motive European Power Brake Bleeder w/ Adapter
• Genesis Cable Bleeder Bottle
• Turkey baster or syringe to suck out old brake fluid
• 17 mm socket and ratchet to remove wheels
• Torque wrench for wheel lugs
• Jack and jack stands

Parts:

• Brake fluid:
• 2 x ATE Original SL.6 DOT 4 . Lower viscosity, better for street use. 
• 2 x ATE Original TYP 200 DOT 4

Recommended:

• Shop rags or towels to place around brake reservoir and underneath brake caliper for spills.

Steps:

• Break torque on wheel lugs using 17 mm socket and ratchet
• Safely jack up E39 and place on jack stands.
• I use Jack pad adapters to prevent crushing the plastic jack points. 
• Remove lug nuts and wheels. 
• Pop open hood and locate driver side cabin air filter tray.
• Use a flat head screw driver and push down on the plastic tabs to disconnect air duct. (Red)
• Unclip metal latch holding air filter cover. (Purple)
• Remove air filter tray cover. (Yellow)
• Remove cabin micro filter. 
• Remove rubber trim around cabin filter tray. 
• Disconnect electrical plug from hood sensor. (Green)
• Squeeze and remove metal clip from screw holding tray to body of vehicle. (Blue)
• Lift and remove cabin air tray.
• Now you have access to the brake fluid reservoir.

• Open reservoir cap (red circle) and suck out old brake fluid with a turkey baster. 
• Place rags or towels around reservoir to soak up spills. Brake fluid will damage and remove paint. 

• Fill brake reservoir to max with new DOT 4 brake fluid. 
• Dump remaining brake fluid into Motive brake bleeder. 
• Install adapter to brake fluid reservoir.
• Pump brake bleeder to 15 psi.

• Go to right rear brake caliper and locate the brake bleeder nipple. 
• Now is a good time to inspect brake lines for any wear, rot, or damage. 

• Remove cover from bleed screw and attach hose from bleeder bottle. 
• If using 9 mm box end wrench, place it on bleed screw before attaching hose from bleeder bottle.
• I sprayed penetrating oil on the screws for ease of loosening. 
• Loosen bleed screw and wait until all the air bubbles and dirty brake fluid has left the hose.
• Look for new, clear brake fluid before tightening bleed screw. 

• Remove hose and reinstall cover. 
• Pump Motive power bleeder to 15 psi.
• Repeat the process for the left rear caliper, right front caliper and finally the left front caliper.
• Make sure power bleeder is at 15 psi before each bleed. 
• When completed, remove pressure from the power bleeder side and fill reservoir to max. 
• Reinstall reservoir cap.
• Reinstall cabin micro filter tray and rubber trim piece. 
• Reinstall and torque wheels.
• Jack and remove jack stands to lower E39. 
• Test the brakes by moving a few feet before going on a drive. 

Notes:
Buy two 1-Liter bottles of brake fluid. One should be enough, but you want to have an extra liter in case of spills or shortage of fluid.

Gently loosen and tighten the brake bleed screws, it is easy to strip and damage them.

It is normal to have air bubbles in the hose from the power bleeder to the reservoir during fluid flush process.

Cover all areas where brake fluid may spill. Brake fluid will strip paint.

Minimize the amount of time new brake fluid will be exposed to air. Brake fluid is hygroscopic so remove the reservoir cap only when necessary. Properly dispose of any opened brake fluid bottles if not using in the near future.

This tutorial may apply to other BMW models.

I don't think the previous owner ever changed the brake fluid or within the past five years. The old brake fluid was extremely nasty and almost black.

  

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