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DrLeadFoot

SCHLEPN | The E39 540itA Story

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For my sanity, I am going to go from most recent work done to the wagon and work backwards. 

Let's jump in!

177,XXX miles.

New power steering pump installed.  I think previous owner ran over something going in reverse as the bumper was pulled down (see zip tie holding bumper).   The power steering upper front mount was cracked making the pulley cockeyed and finally leading to an annoying squeaky belt.

New belt tensioner, front and rear OEM rotors

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New tie rods and steering links.  I never new these things, along with the M5s, have steering boxes.  Brings be back to my Jeep days.

The driver's upper rear control arm nut kept loosening up and making the rear tire pigeon toed.  Prime example to spend the money and buy BMW parts.  PO flipped this and cheaper out here and there.

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Did a timing chain tensioner for good measure just to know a new one is in there.  PO did the chain & guides.  

Threw in a ignition switch as well to try an combat a starting issue.  With 5 series I guess you can just flip the key to the crank-over position for a quick second and it will continue to crank until it starts.  Sometimes I just get a click on the first flick of key and need to flick it in the crank position again for it to fully crank and start.

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Getting the trunk as silent as possible.  Some sound deadening, new OEM weather stripping, tailgate stops and a bunch of glue.  With that being said, a new tailgate is on the radar.  This one is a bit rusty and patched together. 

New grip strip to replace the corroded one.

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Let's jump to the beginning! 

I was all over the internet for a couple months searching for e39 wagon.  I6 or V8 just clean.  I found this 540it for $3700 in New Hampshire that the seller just did the timing chain & guides. I booked a plane ticket and let the older seller know in was coming and had cash.  He didn't believe that someone would fly halfway across the country for this wagon.  Some pics of his garage and first pics of the wagon after the drive to Syracuse, NY:

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It smelled liked mold, air suspension was deflating overnight, alignment was way off and tires were bad. Made it to Syracuse no problem.  Windows down the majority of the way.  The smell was BAD.

Stayed in this sweet late 1800s airbnb. 

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Operation de-mold!  Gallons of vinegar and scrubbing. 

Trans pulled, rear main seal and the other two rear seals replaced. 

New fuel purge valve. 

Popped in 72mm E60 hubs/bearings to dump the 74mm e39 hubs.

New Guibo and CSB new OEM BMW.

Rebuilt the stater while in was in there.

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New trans fluid and filter.  Redline ATF.

19" apex arc-8 et22 275 rears.

Rear sway bar links and bushings. 

New OEM BMW passenger side air bag and both expansion tanks.

KW coilovers and rear adjustable links & KW rear shocks.

Rear drivers side lower ball joint.

New diff output seals.

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The car didn't come with rear shades but I found some shade door cards but had to new new OEM shades as the ones with the doors were ripped.

Started switching all the chrome window trim, inside & out to the black sport trim. With new interior & exterior weather stripping as well.

Air suspension troubleshooting headaches engaged. Had to get a new pump.  New pump was leaking so got a new, new pump.

New, used, front drives window regulator. 

Replaces some old hose clamps with the crimp style.  Got the winter tires/wheels ready to go. 

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Crank case vent was making a horn noise.  Dug into it and found a bunch of sketchy stuff from a PO.  They tried to bypass the CCV and run it through the weird catch can I posted about earlier. One hose for that catch can was being pinched by the intake manifold. So weird.

Glad I was able to get into the top of the motor to replace all the brittle things.

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