How to Replace E34 535 Brakes

The E34 Series of BMWs lasted from 1989 to 1996, and the final year of the E34 BMW 535 was 1993. The 1993 model 535's front brake pads require periodic replacement, typically every 25,000 to 35,000 miles. Driving habits have a lot to do with the longevity of your vehicle's brake pads; stop-and-go traffic or heavy hauling can accelerate pad wear. Though the E34 535 is a high-end and complex vehicle, its front brakes are typical of many cars.

Instructions

Open the 535's hood and remove the lid from the master cylinder reservoir, the plastic container near the rear driver's side of the engine compartment. Siphon out one-quarter of the fluid using the turkey baster, and transfer the fluid to a small, clean container.

Loosen, but do not remove, the 535's lug bolts from the front wheels, using the ratchet, socket and the vehicle's lug bolt key.

Raise the front of the vehicle with the floor jack, and place jack stands beneath the frame rails. Lower the 535 until the weight of the vehicle is only on the jack stands.

Remove the lug bolts from the wheels and pull the wheels from the vehicle.

Place the pry bar under the metal retaining clip on the outside of the brake caliper, and pry it up and off of the caliper. Take note of how it is positioned as it must be replaced in the same fashion.

Loosen and remove the plastic caps covering the caliper slide bolts, on the rear of the caliper, using a ratchet and socket. Loosen and remove the upper and lower caliper slide bolts, on the rear of the caliper, using a ratchet and a hex-bit socket. Disconnect the brake pad sensor harness, the wiring harness plugged into the rear of the caliper, by pressing the locking button and pulling the harness.

Pull the caliper from the brake assembly and hang it from a suspension component, using the bungee strap. Notice the outer pad remains on the brake assembly and the inner brake pad remains on the caliper.

Grab the outer brake pad and remove it from the brake assembly.

Place the C-clamp over the caliper. Position it so the fixed portion is contacting the rear of the caliper and the screw side touches the inner brake pad. Tighten the C-clamp, noting that the inner brake pad begins to press toward the caliper's body. Continue tightening until the brake pad stops moving.

Loosen and remove the C-clamp from the caliper. Grab the inner brake pad and pull it from the caliper. Three finger-like clips hold the pad in the caliper piston.

Place the new outer brake pad on the brake assembly, just as the old one was positioned. Place the inner brake pad inside the caliper, and position the finger-like clips so they are lined up with the hole in the caliper piston. Press the pad down until it sits flat on the caliper.

Remove the caliper from the bungee strap and place it back on the brake assembly.

Cover the caliper slide pins with a thin coat of disc brake grease, reinsert the pins in the rear of the caliper and tighten them to between 18 and 22 foot-pounds, using the torque wrench and a hex-bit socket. Place the metal retaining clip back on the outside of the caliper, and press the clip until it snaps into place.

Place the caps back over the caliper slide pins and lightly snug them with the ratchet and a socket. Plug the brake pad sensor harness back into the rear of the brake caliper.

Repeat Steps 5 through 14 for the pads on the other side of the vehicle.

Place the wheels back on the vehicle and hand-tighten the lug bolts, using the vehicle's lug bolt key.

Raise the 535, using the floor jack, remove the jack stands and lower the vehicle to the ground. Tighten the lug bolts to between 65 and 79 foot-pounds, using the torque wrench and a socket.

Press and release the brake pedal repeatedly, until the pedal feels firm.

Check the fluid level in the master cylinder reservoir. Make certain it rests between the "Min" and "Max" lines. If the fluid level is not between the lines, add fluid from the small container as necessary.