2000 BMW X5

2000-06 BRAKES Disc - X5 (E53)

2000-06 BRAKES

Disc - X5 (E53)

DESCRIPTION & OPERATION

WARNING: Brake friction materials such as brake linings or pads contain abrasive
fibers which can lead to illnesses. Do not create dust by grinding or
sanding, or cleaning the pads with compressed air. Wash away or
vacuum up brake dust. Avoid breathing any brake friction fibers or dust.

WARNING: Brake fluid is poisonous, highly corrosive and dangerous to the

environment. Wear safety glasses and rubber gloves when working with
brake fluid. Do not siphon brake fluid with your mouth. Use a siphon
system dedicated to brake fluid only. Immediately clean away any fluid
spilled on painted surfaces and wash with water. Dispose of brake fluid
properly.

CAUTION: Do not reuse self-locking nuts, bolts or fasteners. They are designed to be
used only once and may fail if reused. Always replace them with new self-
locking nuts. Ensure cleanliness and only use rags which do not lose lint.
Ensure that no oils or grease enter the brake system. These substances
would cause complete failure of the entire brake system. When cleaning
brake components with brake cleaning fluid, none must enter the brake
system.

NOTE: For information on Anti-Lock Brake Systems (ABS), see ANTI-LOCK/TRACTION

CONTROL article.

The brake system is one of the most important safety systems on any motor vehicle. For this reason it is
necessary to exercise particular caution when working on the brake system and to comply with all instructions.

Brake system is hydraulically-operated, using a tandem master cylinder and power brake booster. Some models
use a power steering pump driven booster. All models are equipped with single piston front and rear disc brake
calipers. A brake pressure regulator is used to reduce fluid pressure to rear brakes.

Parking brake is cable actuated on rear brake and consists of internally mounted parking brake shoes. Basic
adjustment of the parking brake is required whenever:

1. Brake shoes are replaced.

2. Brake discs are replaced.
3. Bowden cable is replaced.
4. Bowden cable guide tube is replaced.
5. Adjusting unit is reset.
Microsoft
Sunday, June 20, 2010 9:29:39
9:29:35 AM Page 1 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

6. Actuating stroke is excessive.

BLEEDING BRAKE SYSTEM

BLEEDING PROCEDURES

CAUTION: Use only clean brake fluid. Ensure no dirt or other foreign matter
contaminates brake fluid. DO NOT mix different brands of brake fluid, as
they may not be compatible. DO NOT spill brake fluid on car, as it will
damage paint. If brake fluid contacts paint, immediately flush with water.

CAUTION: The 4.6is with M62S engine requires brake fluid DOT4 (low viscosity). All
other models can be filled with the same brake fluid.

NOTE: Check relevant operating instructions for each device. Charging pressure
should not exceed 29 PSI (2 bar).

1. Connect BMW Diagnosis and Information System (DIS).

2. Call up service function Bleeding ABS/DSC3 Hydraulics.
3. Connect bleeding unit to expansion tank and switch on.
4. To flush system completely see FLUSHING BRAKE SYSTEM COMPLETELY.
5. To only bleed front or rear system see BLEEDING FRONT OR REAR-AXLE BRAKE CIRCUIT.
6. Switch off bleeder unit and disconnect from expansion tank.
7. Check brake fluid level.

NOTE: Take care of rubber gasket in lid.

8. Close expansion tank.

Flushing Brake System Completely

1. Connect bleeder hose with container to bleed valve on rear right brake caliper.
2. Open bleed valve and flush until clear, bubble-free brake fluid emerges.
3. Close bleeder valve.
4. Follow same procedure at rear left, front right, then front left calipers.

Bleeding Front Or Rear-Axle Brake Circuit

1. Connect bleeder hose with container to bleed valve on right brake caliper.
2. Open bleed valve.
3. Run bleeding routine with BMW Diagnosis and Information System (DIS) with bleeder valve open.
4. After running routine, press brake pedal 5 times to stop. Clear, bubble-free brake fluid must flow out.
Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 2 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

5. Close bleeder valve.

6. Repeat procedure at left caliper.

Testing And Bleeding Brakes E53

TESTING AND BLEEDING BRAKES E53 SPECIFICATIONS

Leak test with engine stopped: if applicable
discharge vacuum reservoir by operating brake
pedal firmly about 10 times
Approx. force on pedal approx. N 500
equals approx. line pressure approx. bar 33
Max. pressure drop within 2 min. % 8
Brake booster function test 75 ... 90
(with engine running)
Approx. force on pedal approx. N 200
Line pressure bar

ADJUSTMENTS
PARKING BRAKE

NOTE: Accurate adjustment of the parking brake is only possible if the Bowden cables
and all moving parts move easily and function correctly.

Parking brake adjustment is necessary when:

 Replacing parking brake shoes.

 Replacing brake discs.
 Resetting adjustment unit
 Excessive actuation stroke (10 teeth).
 Replacing parking brake Bowden cables.

Basic Setting

1. Lift out dust cover.

2. Using special tool 34 1 030, release lock nuts and completely loosen Bowden cables. See Fig. 1.
3. Completely remove one wheel stud on each wheel.
4. Rotate wheel until open hole is located at bottom.
5. Insert screwdriver into rotor inspection hole and turn adjusting screw until it is no longer possible to turn
wheel. See Fig. 2.
6. Back off adjusting screw 12 notches.

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 3 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 1: Loosening Parking Brake Bowden Cables

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 4 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 2: Turning Adjusting Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Setting Bowden Cables

1. After basic setting has been completed, the adjustment nuts must be uniformly hand-tightened before the
Bowden cables are adjusted.
2. Tighten parking brake lever 5 times to approximately 400 N hand-lever force with the release button
pressed.

Setting By Hand

1. Apply 2 teeth of parking brake lever and adjust adjusting nuts until braking action begins.
2. Release parking brake lever. It must be possible to turn wheels easily.
3. Switch ignition on. Indicator light must not be on when parking brake lever is released. At the first tooth
Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 5 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

with no breaking effect, the indicator light may be lit. At the second tooth the light must be lit. If not the
switch contact on the lever must be adjusted.

Setting On Roller Dynamometer

WARNING: Use only brake dynamometers whose test speed is 3 mph (5 km/h) or
less. Follow without fail the guidelines contained in the operating
instructions of the relevant test stand manufacturer. Failure to do so may
result in damage to the vehicle and the system and also personal injury.

CAUTION: The maximum test duration for four-wheel drive vehicles is 3 minutes per
axle. If the test has to be repeated, the vehicle must be driven over a
distance of at least .6 miles (1 km) to ensure the transfer case is
sufficiently lubricated.

Check tires for damage. Check tire treads. Check tire pressures.

NOTE: On cars equipped with ASC+T or DSC, the system must be deactivated with the
switch. ASC+T/DSC indicator lamp in instrument cluster must light up.

The brakes must be at normal operating temperature. To achieve this, brake the car several times to slightly
warm and dry brake discs and drums.

1. With parking brake released, shift transmission into neutral. Wheel circumferential force at idle should be
less than or equal to 150 N.
2. At first tooth, there is no brake force increase. Indicator lamp may be lit.
3. At second tooth, indicator lamp must be lit.
4. At third tooth, adjust parking brake cables until brake force indicator shows 500-550N.

Breaking In Duo-Servo Parking Brake

The following breaking in procedures are applicable in case of insufficient braking effect or after replacing
brake discs and/or brake shoes.

WARNING: Use only brake dynamometers whose test speed is 3 mph (5 km/h) or
less. Follow without fail the guidelines contained in the operating
instructions of the relevant test stand manufacturer. Failure to do so may
result in damage to the vehicle and the system and also personal injury.

CAUTION: The maximum test duration for four-wheel drive vehicles is 3 minutes per
axle. If the test has to be repeated, the vehicle must be driven over a
distance of at least .6 miles (1 km) to ensure the transfer case is
sufficiently lubricated.

Check tires for damage. Check tire treads. Check tire pressures.
Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 6 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

NOTE: On cars equipped with ASC+T or DSC, the system must be deactivated with the
switch. ASC+T/DSC indicator lamp in instrument cluster must light up.

The brakes must be at normal operating temperature. To achieve this, brake the car several times to slightly
warm and dry brake discs and drums.

1. On roller dynamometer, actuate parking brake lever until the wheel circumferential force on both wheels
is at least 800 N. Release lever after approximately 40 seconds.

NOTE: Do not do this procedure if parking brake cables are not adjusted
uniformly.

2. When driving on road (where possible on private property or quiet road), at approximately 40 km/h, apply
parking brake lever until braking action can be felt. Pull up lever into next catch and drive on for
approximately 400 m.
3. Repeat breaking in procedure if necessary. Allow brakes to cool down sufficiently.

TROUBLESHOOTING
Brake performance is mainly affected by 3 things: the level and condition of the brake fluid, the brake system's
ability to create and maintain hydraulic pressure, and condition of the friction components. Tires and wheels are
important parts of the braking system. Check tires for wear, flat spots, trueness and proper inflation. Visually
check the hydraulic system starting at the master cylinder. Check all brake fluid lines and couplings for leaks,
kinks, chafing and corrosion.

On vehicles with vacuum brake booster, check brake booster by pumping brake pedal approximately 12 times
with the engine off. Then hold down brake pedal and start engine. Pedal should fall slightly. If not, check for
any visible faults before suspecting a faulty brake booster. Check for strong vacuum at vacuum hose fitting on
booster. Ensure vacuum check valve has one-way flow. For trouble shooting symptoms, see SYMPTOM
INDEX table.

SYMPTOM INDEX
Symptom See Symptom Table
Brakes Pull To One Side A
Brakes Excessively Hot While Driving B
Poor Braking Effect In Spite Of Great Force On C
Pedal, Brake Pedal Travel Normal
Poor Braking Effect In Spite Of Great Force On C
Pedal, Brake Pedal Travel Short
Poor Braking Effect In Spite Of Great Force On C
Pedal, Brake Pedal Travel Long
Brake Pedal Motion Too Soft & Spongy D
Brake Pedal Travel Is Excessive Even Though E
Brakes Have Been Bled & Adjusted

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 7 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Uneven Pad Wear F

Brake Pads Worn At Angle G
Seized Brake Pads, Pad Does Not Move Off Brake H
Disc
Brakes Squeal Or Rattle I
Brake Pedal Dead Travel Excessive J
Jammed Piston In Brake Caliper K
Pulsating Effect On Brake Pedal L
Parking Brake Effect Insufficient M

SYMPTOM A: BRAKES PULL TO ONE SIDE

SYMPTOM A: BRAKES PULL TO ONE SIDE

Possible Cause Solution
Tire Pressure Incorrect Bring Tire To Correct Pressure
Unevenly Worn Tire Treads Change Or Replace Tires
Oil On Pads Replace Brake Pads, Check For Source Of Oil
Wrong Type Of Pads Replace Brake Pads
Dirty Floating Caliper Recesses Remove & Install Clean Floating Calipers
Guide Bolts Dirty Or Damaged Replace Guide Bolts
Rear Wheel Alignment Adjusted Incorrectly Check Wheel Alignment
Corrosion In Floating Calipers Remove & Install, Repair Or Replace Floating
Calipers
No Shock Absorber Action Check Shock Absorbers & Replace If Necessary
Pad Of One Caliper Worn Replace Brake Pads, Check Floating Caliper
Pad Glazed Replace Brake Pads, Check Floating Caliper

SYMPTOM B: BRAKES EXCESSIVELY HOT WHILE DRIVING

SYMPTOM B: BRAKES EXCESSIVELY HOT WHILE DRIVING

Cause Solution
Vent Bore In Master Cylinder Clogged Overhaul Master Brake Cylinder
No Play Between Push Rod & Master Cylinder Adjust Push Rod
Piston
Swollen Rubber Parts Due To Use Of Wrong Brake Flush Brake System, Overhaul Master Brake
Fluid Cylinder, Or Replace If Necessary
Vent Bore In Expansion Tank Clogged Clean Expansion Tank
Corroded Floating Calipers Remove & Install, Repair Or Replace Floating
Calipers
Cross Spring Broken Replace Cross Spring
Parking Brake Lever Not Released Fully Check Parking Brake & Parking Brake Cables,
Repair If Necessary

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 8 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

SYMPTOM C: POOR BRAKING EFFECT

SYMPTOM C: POOR BRAKING EFFECT

Travel Cause Solution
Normal Brake Pads Oil-Splattered Or Burnt, Wrong Replace Brake Pads
Type Of Brake Pads
Short Brake Booster Malfunctions- Engine Vacuum Check Brake Booster System -
Check Engine (Valves, Cylinder
Head Gasket, Etc.)
Long One Brake Circuit Failed Due To Leaks Or Find & Repair Leak(s) Or
Damage Damage

SYMPTOM D: BRAKE PEDAL MOTION TOO SOFT & SPONGY

SYMPTOM D: BRAKE PEDAL MOTION TOO SOFT & SPONGY

Cause Solution
Air In Braking System Top Up Or Change Brake Fluid, Bleed Brake
System
Insufficient Brake Fluid In Expansion Tank Top Up Or Change Brake Fluid, Bleed Brake
System
Overheated Brake Fluid, Vapor Lock Due To Top Up Or Change Brake Fluid, Bleed Brake
Excessive Water Content In Brake Fluid Or System
Excessive Brake Loads

SYMPTOM E: BRAKE PEDAL TRAVEL EXCESSIVE

SYMPTOM E: BRAKE PEDAL TRAVEL EXCESSIVE

Cause Solution
Primary Cup In Master Cylinder Damaged Overhaul Or Replace Brake Master Cylinder
Separating Cups On Floating Piston Of Tandem- Overhaul Or Replace Brake Master Cylinder
Brake, Master Cylinder Leak
Leak In Braking System Find & Repair Leak(s)

SYMPTOM F: UNEVEN PAD WEAR

SYMPTOM F: UNEVEN PAD WEAR

Cause Solution
Wrong Type Of Pads/Liners Replace Brake Pads
Dirty Floating Caliper Recesses, Damaged Caps Remove & Install, Repair Or Replace Floating
Calipers
Corrosion In Floating Calipers Or Wheel Cylinders Remove & Install, Repair Or Replace Floating
Calipers
Swollen Rubber Ring For Piston Control Remove & Install, Repair Or Replace Floating
Calipers
Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 9 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

SYMPTOM G: BRAKE PADS WORN AT ANGLE

SYMPTOM G: BRAKE PADS WORN AT ANGLE

Cause Solution
Wheel-Bearing Play Excessive Replace Wheel Bearings
Brake Disc Not Aligned With Floating Caliper Check Floating Caliper Installation
Corrosion In Floating Calipers Remove & Install, Repair Or Replace Floating
Calipers
Angular Brake-Disc Wear Grind Or Replace Brake Discs
Pads Worn To Less Than Minimum Thickness Replace Brake Pads
Spring Force Insufficient Replace Spring
Guide Bolts Damaged Replace Guide Bolts

SYMPTOM H: SEIZED BRAKE PADS

SYMPTOM H: SEIZED BRAKE PADS

Cause Solution
Dirty Floating Caliper Recesses, Damaged Caps Remove & Install, Repair Or Replace Floating
Calipers
Corrosion In Floating Calipers Remove & Install, Repair Or Replace Floating
Calipers
Vent Bore In Master Cylinder Clogged Overhaul Or Replace Brake Master Cylinder

SYMPTOM I: BRAKES SQUEAL OR RATTLE

SYMPTOM I: BRAKES SQUEAL OR RATTLE

Cause Solution
Wrong Type Of Pads/Liners Replace Brake Pads
Dirty Floating Caliper Recesses Remove & Install Clean Floating Calipers
Spring Force Insufficient Replace Spring
Brake Disc Not Aligned With Floating Caliper Check Floating Caliper Installation
Brake-Disc Runout Check Brake Disc for Runout, Replace If Necessary
Excessive Thickness Deviation Within Braking Measure Thickness Of Brake Disc, Grind Down
Surface Discs Or Replace
Pad Wear Excessive Or One-Sided Replace Brake Pads
Rust Edges On Brake Discs Grind Or Replace Brake Discs
Pad Loose Replace Brake Pads
Wheel Bearing Play Excessive Replace Wheel Bearings

SYMPTOM J: BRAKE PEDAL DEAD TRAVEL EXCESSIVE

SYMPTOM J: BRAKE PEDAL DEAD TRAVEL EXCESSIVE

Cause Solution
Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 10 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Wheel Bearing Play Excessive Replace Wheel Bearings

Brake Disc Not Aligned With Floating Caliper Check Floating Caliper Installation
Break Disc Runout Check Brake Disc For Runout, Replacing If
Necessary
Excessive Thickness Deviation Within Braking Measure Thickness Of Brake Disc, Grind Down
Surface Discs Or Replace
Brake System Leaking Find & Repair Leak(s)
Air In Braking System Bleed Brakes
Wrong Type Of Pads Replace Brake Pads Or Replace Brake Shoes

SYMPTOM K: JAMMED PISTON IN BRAKE CALIPER

SYMPTOM K: JAMMED PISTON IN BRAKE CALIPER

Cause Solution
Dirty Floating Caliper Recesses, Damaged Caps Remove & Install, Repair Or Replace Floating
Calipers
Brake Disc Not Aligned With Floating Caliper Check Floating Caliper Installation
Corrosion On Pistons In Floating Calipers Remove & Install, Repair Or Replace Floating
Caliper

SYMPTOM L: PULSATING EFFECT ON BRAKE PEDAL

SYMPTOM L: PULSATING EFFECT ON BRAKE PEDAL

Cause Solution
Wheel Bearing Play Excessive Replace Wheel Bearings
Brake Disc Not Aligned With Floating Caliper Check Floating Caliper Installation
Brake Disc Runout Check Brake Disc For Runout, Replace If Necessary
Excessive Thickness Deviation Within Braking Measure Thickness Of Brake Disc, Grind Down
Surface Discs Or Replace

SYMPTOM M: PARKING BRAKE EFFECT INSUFFICIENT

SYMPTOM M: PARKING BRAKE EFFECT INSUFFICIENT

Cause Solution
Parking Brake Shoes Oil-Splattered Replace Parking Brake Shoes, Determine Cause Of
Splattering
Excessive Dead Travel Between Brake Shoes & Adjust Parking Brake
Brake Drums
Excessive Dead Travel In Cables Adjust Parking Brake
Cables Adjusted Incorrectly Adjust Parking Brake
Corroded Transmitting Elements Remove & Install Parking Brake & Expanding
Locks, Check Bowden Cables & Replace If
Necessary
Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 11 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

TESTING
BRAKE BOOSTER

Low Pressure Test

1. Remove heater bulkhead. See HEATER BULKHEAD.

2. Pull hose off connection. Install vacuum tester 34 3 100 between connection and vacuum hose on non-
return valve. See Fig. 3.
3. Start engine and check buildup of partial vacuum. Stop engine.
4. Press brake pedal to set a partial vacuum of no more than 11.6 PSI (.8 bar) and wait for value to stabilize.
5. When the brake pedal is not pressed, the partial vacuum is allowed to drop by maximum .8 PSI (.06 bar)
over a test period of 1 minute.

If specified values are not reached:

1. Check line connections for vacuum seal.

2. Replace vacuum non-return valve.
3. Check seal between brake booster and brake master cylinder (sealing ring) for perfect condition and
correct seating.
4. If the specified values are not achieved when the test is repeated, you must replace the brake booster.
5. After removing tester, reinstall heater bulkhead. See HEATER BULKHEAD.

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 12 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 3: Installing Vacuum Tester

Courtesy of BMW OF NORTH AMERICA, INC.

BRAKE WARNING LIGHT

Brake warning light is mounted on instrument panel. Turn ignition on and release parking brake. Verify light is
off. Remove master cylinder filler cap. Warning light should come on. If warning light does not come on, check
bulb and circuit connections.

PARKING BRAKE

1. At the first tooth, no braking effect should be present.

2. At the 2nd tooth, braking action can begin and the indicator light may be lit.
3. At the 3rd, tooth, braking action must begin and the indicator light must be lit.
4. At the 4th tooth, braking action increases.
5. At the 5th tooth, wheel circumferential force must be at least 1100 N at one of the two rear wheels, and at
least 1000 N at the other wheel. Wheel circumferential force differential (left to right) maximum 30%
from highest value (shortly before wheel lockup). A readjustment must be carried out in event of larger
Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 13 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

deviations of wheel circumferential force. See PARKING BRAKE under ADJUSTMENTS.

6. Braking with locked wheels must be possible with the parking brake.
7. The ABS/ASC warning lights, if on, will automatically switch off by switching off engine, waiting at
least 30 seconds, restart engine and drive away. Warning lights will go out when speed exceeds 8 mph.
(Fault codes will be retained in memory.)
8. The parking brake must be readjusted whenever the actuation stroke is greater than 10 teeth.

SERVICE BRAKE

NOTE: High-pressure and low-pressure tests (leakage test) must be performed with the
engine switched off.

High-Pressure Test

NOTE: Perform test on both brake circuits, front and rear.

1. Unscrew vent plug, connect pressure tester and vent. See Fig. 4.
2. Load brake pedal with a force of approximately 112 lbs. (500 N), and block pedal with pedal support.
Line pressure should be approximately 479 PSI (33 bar).
3. After 2 minutes, pressure must not drop by more than 8 percent.
4. Perform low-pressure test.

Low-Pressure Test

NOTE: Perform test on both brake circuits, front and rear.

1. Reset pedal support until line pressure in brake system is equal to 30-72 PSI (2-5 bar). Car and measuring
equipment must remain perfectly still as vibrations will distort the result.
2. Pressure should remain constant during five minute test.
3. Check all rubber parts in case of excessive pressure drop.
4. Bleed brake calipers after finishing test.

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 14 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 4: Connecting Pressure Tester

Courtesy of BMW OF NORTH AMERICA, INC.

THICKNESS OF BRAKE LINING

NOTE: The thickness of the outer brake linings can be determined without removing
the wheels.

1. If necessary, move car until opening for brake lining wear indicator (brake lining) can be seen through
rim styling.
2. Insert special tool (34 1 260) through rim into opening for brake lining wear indicator.
3. Press special tool onto brake lining. Slide ring (1) in direction of arrow as far as it will go and read off
measured value. See Fig. 5.
4. Minimum thickness for all models is stamped in brake disc shell. Wear warning from residual lining
thickness is 3 mm. Maximum machining limit per friction ring side is .8 mm. For minimum thickness see
BRAKE LINING MINIMUM THICKNESS table.

BRAKE LINING MINIMUM THICKNESS

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 15 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Application In. (mm)

Front 1.12 (28.4)
Rear .72 (18.4)

Fig. 5: Measuring Thickness Of Brake Lining

Courtesy of BMW OF NORTH AMERICA, INC.

REMOVAL & INSTALLATION

BRAKE BOOSTER

Removal

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 16 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

1. Remove the master cylinder. See MASTER CYLINDER.

2. Remove trim from pedal assembly.
3. Remove brake booster from brake pedal and from engine firewall.
4. Remove emergency siren with holder.
5. Force linkage of windshield wiper arms off wiper motor. Swivel out linkage to side.
6. Detach cover/cowl and fold out towards top.
7. Pull the vacuum hose (3) off of the brake unit. See Fig. 6.

CAUTION: Do not use any force when removing and installing the brake booster
unit. The unit can be damaged under certain circumstances.

8. Carefully swing out the brake booster and remove towards top.

Fig. 6: Removing Booster Components

Courtesy of BMW OF NORTH AMERICA, INC.

Installation
Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 17 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

1. Carefully insert brake booster unit into place.

2. Push pedal assembly into place and replace self-locking nuts.
3. Balance of assembly is reverse of removal.

BRAKE BOOSTER NON-RETURN VALVE

Removal & Installation

1. Press the brake pedal several times to reduce the vacuum in the brake booster, making it easier to pull off
the vacuum hose.
2. Remove heater bulkhead. See HEATER BULKHEAD.
3. Open hose clips and pull non-return valve out of brake unit and detach from vacuum hose.
4. To install, reverse removal procedure.

BRAKE BOOSTER VACUUM HOSE

Operation is identical to replacing non-return valve with the addition of removing vacuum hose on suction jet
pump. See BRAKE BOOSTER NON-RETURN VALVE.

BRAKE DISCS

CAUTION: If the thickness of the brake discs drops below the minimum the discs
must be replaced. Always replace discs in pairs. If the discs are replaced,
you must also fit new brake pads.

Removal

1. Raise and support vehicle. Remove wheel(s).

2. If necessary, remove and clean disc pads. See BRAKE DISC PADS.

NOTE: Brake hose remains connected.

3. Remove caliper mounting bolts and raise caliper off mounting assembly and suspend from vehicle with
wire.

CAUTION: To release brake disc, do not strike friction ring with a hammer or
similar. If necessary, carefully tap on base of brake disc chamber
with a rubber mallet.

4. Unscrew bolts and take off brake disc. See Fig. 7.

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 18 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 7: Removing Brake Disc

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

CAUTION: Internally ventilated brake discs are balanced. Never remove or reposition
balance clips.

1. Thoroughly clean contact surface of brake disc at wheel hub. Remove traces of corrosion if necessary.
Unevenness on contact surface may result in distortion of brake disc.
2. Install brake disc and tighten bolts to specification. See TORQUE SPECIFICATIONS.
3. If removed, install brake pads.

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 19 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

4. Check that brake hose has not been disconnected. If disconnected make sure it is positively attached.
5. Replace caliper and tighten screws to specification. See TORQUE SPECIFICATIONS.
6. Install wheels and bleed brakes if brake hose was disconnected.
7. If work was on rear brakes, adjust parking brake. See PARKING BRAKE under ADJUSTMENTS.

BRAKE DISC PADS

Removal

1. Raise and support vehicle. Remove wheel(s).

2. Lift out retaining spring (1). See Fig. 8.
3. On left front side, disconnect plug connection for brake lining wear indicator. On right rear side,
disconnect plug connection for brake pad sensor.
4. On all sides, remove plastic plugs (2). See Fig. 9.
5. Lift brake hose out of bracket.
6. Release guide screws (1) with special tool 34 1 080. See Fig. 10. Withdraw brake caliper backwards.
7. Check threads. Replace all guide screws which are not in perfect condition.

CAUTION: When forcing piston back, pay attention to brake fluid level in
expansion tank. Brake fluid that spills over will damage paintwork.

8. Turn piston fully back with special tool 34 1 050. See Fig. 11.
9. Remove outer brake pad. Inner brake pad is located with its spring in the piston.
10. Mark any worn brake pads. In the event of one-sided brake lining wear, do not change brake pads around.
11. New brake linings may only be installed if the brake disc thickness is greater than or equal to the
minimum thickness. See BRAKE SPECIFICATIONS.
12. Clean brake pads.
13. Do not apply grease to brake pad backplate.

CAUTION: Dust sleeve must not come into contact with ant-squeak compound
as this would cause dust sleeve to swell.

14. Check dust sleeve (1) for damage and replace if necessary. Clean contact face (2) of brake piston and
apply a thin coating of anti-squeak compound. See Fig. 12.
15. Clean contact faces (1,2) of brake pad hammer heads/brake caliper housing and coat with anti-squeak
compound. See Fig. 13.
16. Grease contact surfaces on brake caliper at top and bottom.
17. Clean contact face (3) of brake caliper and apply a thin coating of anti-squeak compound. See Fig. 14.
18. Clean contact face of brake caliper mounting bracket and apply a thin coating of anti-squeak compound.

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 20 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 8: Locating Retaining Spring

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:35 AM Page 21 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 9: Locating Plastic Plugs

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 22 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 10: Locating Guide Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 23 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 11: Forcing Piston Back

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 24 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 12: Locating Dust Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 25 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 13: Locating Contact Faces

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 26 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 14: Locating Contact Face Three

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

1. The piston side front brake pads are directional. Install brake pad with identification mark "L" on left and
"R" on right side of vehicle.
2. Use only clean guide screws to install caliper. Do not grease. Tighten to specification. See TORQUE
SPECIFICATIONS.
3. Make sure the brake hose is positively attached in the mounting fixture.
4. Install plastic plugs.
5. Connect plug connection for brake pad wear indicator in front and pad sensor in rear.
6. Fully depress brake pedal several times so that brake pads contact brake discs.
7. Bring brake fluid level up to "MAX" marking.
Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 27 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

8. Hold ignition key for at least 30 seconds in position "1" without starting engine. This clears a fault entry
in the RAM. This prevents the brake wear indicator lamp from lighting up again.

BRAKE EXPANSION TANK

Removal & Installation

1. Remove cover/microfilter.
2. Suck the brake fluid out of the expansion tank. Use a suction device used exclusively for drawing off
brake fluid.
3. Unfasten plug connection and disconnect.
4. Pull supply hose (1) off of clutch hydraulic system, if equipped. See Fig. 15.
5. Press left and right retaining lugs apart.
6. On vehicles with a precharging pump for DSC, the supply hose must be secured in a vertical position to
prevent fluid from emerging.
7. Lift out the expansion tank from the master brake cylinder by tilting it laterally.
8. Check rubber plug in master brake cylinder. No damage may be present.
9. Push the expansion tank vertically onto the master brake cylinder.
10. Connect hoses, fill expansion tank, and bleed system.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 28 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 15: Locating Supply Hose Of Clutch Hydraulic System

Courtesy of BMW OF NORTH AMERICA, INC.

BRAKE LIGHT SWITCH

Removal & Installation

1. Remove trim for pedal assembly.

2. Depress brake pedal as far as possible, using pedal support if necessary.
3. Pull tappet and sleeve forward completely (1). Press together clips and pull back switch (2). See Fig. 16.
4. A gap of .7 mm must be set between brake pedal and brake light switch. If this fails to ensure correct
operation, it must be reduced to .6 mm.
5. To install, reverse removal procedure.
6. Slowly bring brake pedal into initial position.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 29 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 16: Removing Brake Light Switch

Courtesy of BMW OF NORTH AMERICA, INC.

BRAKE LINES

CAUTION: The rear brake lines are secured on the upper control arm by line holders.
The flaps of the line holders must not be opened. If this does occur,
replace the holders.

New Brake Line Precautions

1. Protective coating on brake lines must not be damaged while bending.

2. Brake lines must not be bent back and forth.
3. Watch distances to fixed and movable vehicle parts. Brake lines must not contact or rub.
4. Tighten brake line couplings with torque wrench to specifications. See TORQUE SPECIFICATIONS.

Removal & Installation

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 30 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

1. Apply pedal prop and depress brake pedal slightly. This prevents brake fluid from flowing out of
expansion tank and into brake system when brake lines are opened.
2. Disconnect brake hose from line.

NOTE: Brake pipes are only supplied straight, in correct length and fitted with
connecting nipples.

3. Bend new pipe as required using bending tool 34 5 100. Removed pipe can be used as template.
4. If replacing front brake pipe, move wheels into straight-ahead position. Install new pipe and tighten to
specification. See TORQUE SPECIFICATIONS.
5. Remove pedal prop and bleed brake system. See BLEEDING BRAKE SYSTEM.

CALIPER ASSEMBLY

CAUTION: After completing work, bleed brake system. See BLEEDING BRAKE
SYSTEM.

Removal

1. Raise and support vehicle. Remove wheel(s).

2. Apply pedal support and press brake pedal slightly. This prevents brake fluid from emerging from
expansion tank and air from entering the brake system after the brake lines have been detached.

CAUTION: The rear brake hose is secured on the upper control arm by a line
holder. The flaps of the line must not be opened. If this happens, the
holder must be replaced.

3. Loosen bolts (1). Use special tool 34 1 080. Disconnect brake hose (2). See Fig. 17.
4. On right rear disconnect plug connection for brake lining sensor. On left front remove connector for wear
indicator.
5. Lift brake hose out of bracket.
6. Withdraw brake caliper backwards.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 31 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 17: Disconnecting Brake Hose

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

CAUTION: Check routing and securing of brake pad wear sensor cable. Check for
correct securing with tab of dust cap. Rubbing of cable on rim must be
prevented.

1. To install, reverse removal procedure.

2. Only clean guide screws. Do not grease. Check threads. Replace all guide screws which are not in perfect
condition.
3. Tighten caliper mounting bolts to specification. See TORQUE SPECIFICATIONS.
4. Bleed hydraulic system.
5. Install and tighten wheel bolt. See TORQUE SPECIFICATIONS.

FRONT AXLE WHEEL BEARINGS

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 32 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

See appropriate FRONT article in SUSPENSION.

HEATER BULKHEAD

Removal & Installation

1. Detach sealing strips (1). See Fig. 18.

2. Turn toggles through approximately 90 degrees. See Fig. 19.
3. Lift out cover (1). Unfasten screws and pull out heater bulkhead (2). See Fig. 20.
4. Check rubber seals (1) on left and right and replace if necessary. Coat rubber seals (1) on left and right
with rubber protection coating agent. Heater bulkhead is guided at sides with guide channels. Clean guide
channels and coat with rubber protection coating agent. See Fig. 21.
5. To install, reverse removal procedure.

Fig. 18: Locating Sealing Strips

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 33 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 19: Locating Toggles

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 34 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 20: Removing Heater Bulkhead

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 35 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 21: Locating Rubber Seals

Courtesy of BMW OF NORTH AMERICA, INC.

MASTER BRAKE CYLINDER

Removal

1. Remove cover in luggage compartment and remove grounding strap from body.
2. Suck the brake fluid out of expansion tank. Use a suction device used exclusively for drawing off brake
fluid.
3. Remove brake fluid expansion tank. See BRAKE EXPANSION TANK.
4. Remove heater bulkhead. See HEATER BULKHEAD.
5. Remove positive support point at partition wall on left.
6. Unclip Bowden cable for engine hood locking.
7. Pull wiring harness upwards out of partition wall. Unscrew nuts.
8. Release screws. Remove rubber mount for windshield washer unit. Pull out partition wall.
9. Disconnect all hydraulic lines from master cylinder. See Fig. 22. Close off the brake lines and the master
brake cylinder using appropriate seal plugs.
10. Remove cover (1) from line aperture. Pull the vacuum hose (3) off of the brake unit. See Fig. 23.
Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 36 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

11. Remove master cylinder-to-power booster nuts. Remove support and master cylinder.
12. Replace O-ring. See Fig. 24.

Fig. 22: Locating Screw Connections

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 37 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 23: Removing Vacuum Hose

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 38 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 24: Locating O-Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

1. Install master brake cylinder to brake unit. When inserting master brake cylinder make sure that pressure
rods of brake booster and master brake cylinder lie in one plane. Replace self-locking nuts and tighten to
specification. See TORQUE SPECIFICATIONS.
2. Attach and tighten screw connections of brake lines and tighten to specification. See TORQUE
SPECIFICATIONS.
3. To install, reverse removal procedure.
4. Push the expansion tank vertically onto the master brake cylinder.
5. Refill brake fluid and bleed the system. See BLEEDING BRAKE SYSTEM.

PARKING BRAKE BOWDEN CABLES

Removal & Installation

1. Remove parking brake shoes. See PARKING BRAKE SHOES.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 39 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

2. Pull expander locks (1) forward, disconnect parking brake cables (2), and remove expander locks. See
Fig. 25.
3. Remove rubber gaiter.
4. Release lock nuts with special tool 34 1 030. Screw out lock nuts and adjustment nuts fully from Bowden
cables.
5. Pull parking brake cable out of mounts.
6. Pull parking brake cable out of guide tube and out of wheel carrier.
7. Make sure parking brake cables are correctly laid.
8. Secure adjustment nuts with lock nuts.
9. Install expander locks and connect cables.
10. Adjust parking brake. See PARKING BRAKE under ADJUSTMENTS.
11. Replace rubber gaiter.

Fig. 25: Removing Expander Lock

Courtesy of BMW OF NORTH AMERICA, INC.

PARKING BRAKE SHOES

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 40 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Removal & Installation

1. Raise and support vehicle. Remove rear wheel(s).

2. Remove rear brake disc. See BRAKE DISCS.
3. Disconnect return springs with brake spring pliers. See Fig. 26.
4. Twist clamping pins with special tool 34-4-000 through 90 degrees and disconnect. See Fig. 27.
5. Remove brake shoes.
6. To install, reverse removal procedure. Coat thread of adjusting bushing (1) and screw (2) with grease.
Notice installation position of adjusting screws. See Fig. 28.
7. Check return springs and replace if necessary.
8. Adjust parking brake and check operation. See PARKING BRAKE under ADJUSTMENTS.

Fig. 26: Locating Return Springs

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 41 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 27: Removing Parking Brake Shoes

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 42 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 28: Locating Adjusting Screws

Courtesy of BMW OF NORTH AMERICA, INC.

REAR AXLE WHEEL BEARINGS

Removal & Installation

1. Raise and support vehicle. Remove wheel(s).

2. Unfasten collar nut (1). See Fig. 29. It may be necessary to apply brakes to keep hub from rotating.
3. Remove brake disc. See BRAKE DISCS.
4. Screw special tool 33 2 116 onto drive flange with wheel studs. Drive out drive flange with special tool
33 4 201/202/203. See Fig. 30.
5. If necessary, pull off bearing inner race from drive flange.
6. Unfasten screws and remove wheel bearing. See Fig. 31.

CAUTION: Do not reuse old wheel bearing.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 43 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

7. Install new wheel bearing. The contact faces (2) of wheel bearing and wheel carrier and the tapped bores
(1) must be clean and free of grease. See Fig. 32.
8. Tighten to specification. See TORQUE SPECIFICATIONS.
9. Apply light coat of oil to drive flange (1). Attach drive flange on spline of axle shaft and tighten it down
using special tool 33 2 115/ 116/ 118. See Fig. 33.
10. Install brake disc.
11. Lightly oil and replace collar nut. Tighten to specification. See TORQUE SPECIFICATIONS.

WARNING: Collar nut must be locked.

12. Secure collar nut by caulking it at flat areas of axle shaft.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 44 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 29: Locating Collar Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 45 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 30: Removing Drive Flange

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 46 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 31: Locating Wheel Bearing Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 47 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 32: Locating Contact Faces

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 48 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 33: Attaching Drive Flange

Courtesy of BMW OF NORTH AMERICA, INC.

OVERHAUL
BRAKE CALIPER

Disassembly

1. Remove caliper. See CALIPER ASSEMBLY under REMOVAL & INSTALLATION.

2. Remove pads from caliper. See BRAKE DISC PADS under REMOVAL & INSTALLATION.

WARNING: When pressing out brake caliper piston large forces occur. Be
careful of fingers.

3. Slowly apply air pressure to fluid inlet of caliper to force out piston. To protect piston, place a protective
plate (hard wood or hard felt) in caliper recess. See Fig. 34.
4. Check guide sleeves (5), fitting repair-kit guide sleeve if necessary. See Fig. 35.
Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 49 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

5. Remove sealing ring carefully with a plastic needle. See Fig. 36.
6. Thoroughly inspect cylinder bore, piston and flange surfaces. Machining of cylinders and pistons is not
permitted.

Fig. 34: Pressing Out Piston

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 50 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 35: Locating Guide Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 51 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 36: Removing Sealing Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

1. Coat cylinder bore, piston, dust sleeve and sealing ring with a light coat of brake cylinder paste.

NOTE: Ensure piston is not tilted when installing.

2. Install sealing cover in rear annular groove of cylinder bore. Press in piston with a hardwood board. See
Fig. 37.
3. The area between dust cover and brake caliper housing must be kept dry so as to ensure correct seating
for the dust cover. Keep brake cylinder paste or brake fluid away from this area. Install dust cover evenly
up to stop with special tool 34 1 131. See Fig. 38.
4. For rear use special tool 34 1 132. See Fig. 39.
5. Press brake lining fully outwards and insert spring (4). See Fig. 40.
6. Only clean guide screws, do not grease. Check and replace if necessary. Tighten to specification. See
TORQUE SPECIFICATIONS.
7. Install caliper. See CALIPER ASSEMBLY.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 52 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 37: Pressing In Piston

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 53 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 38: Pressing On Dust Cover (Front)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 54 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 39: Pressing On Dust Cover (Rear)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 55 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 40: Identifying Retaining Spring

Courtesy of BMW OF NORTH AMERICA, INC.

MASTER CYLINDER

Disassembly

Push in primary piston and remove plug. See Fig. 41. Remove retaining ring from end of cylinder. Remove
primary and secondary piston assemblies and stopper washer. Disassemble piston assemblies, noting number
and position of parts used for reassembly reference. See Fig. 41.

NOTE: Replace master cylinder if cylinder bore is scored.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 56 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 41: Exploded View Of Master Cylinder Assembly

Courtesy of BMW OF NORTH AMERICA.

Reassembly

1. Reassemble piston assemblies using thin coating of brake assembly lubricant. Install piston assemblies
into cylinder bore, using Guide Sleeve (34-3-000) to prevent seal damage.
2. Push piston fully forward and install plug. Install retaining ring in master cylinder bore. Replace "O" ring
between master cylinder and brake booster. Bench bleed master cylinder before installation.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Adapter To Power Flow Regulator 12 (16)
Bearing Pedestal To Brake Assembly & Body
Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 57 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

NOTE: Retighten 1x on brake booster after 30 min. 16 (21)

Bleed Screw
7 mm (1)

9 mm 5.2-8.1 (7-11)
11 mm 9-12 (12-16)
Brake Booster To Pedal Assembly Console 23 (31)
Brake Caliper On Semi-trailing Arm/Wheel Carrier 49 (67)
Brake Caliper To Steering Knuckle 81 (110)
Brake Carrier On Semi-trailing Arm/Wheel Carrier 48 (65)
Brake Disc To Wheel Hub Bolt 12 (16)
Brake Hose Couplings 10.3 (14)
Brake hose to brake caliper:
Front 17.7 (24)
Rear 30 (40)
Brake Master Cylinder To Brake Booster (Vacuum) 19 (26)
Collar Nut 310 (420)
Guide Screw, Front 22 (30)
Guide Screw, Rear 21 (28)
Parking Brake Lever To Body 16 (21)
Hydraulic Pipe Coupling To Brake Booster 23 (31)
Hydraulic Pipe From Power Steering Pump On Power Flow 30 (40)
Regulator
Hydraulic Pipe To Brake Booster On Power Flow Regulator 23 (31)
Hydraulic Pipe To Pressure Reservoir 30 (40)
Hydraulic Pipe To Pressure Reservoir On Power Flow Regulator 35 (47)
Hydraulic Pipe To Steering Gear On Power Flow Regulator 37 (50)
Hydraulic Switch (Warning Switch) To Power Flow Regulator 13 (18)
Orifice Valve To Brake Booster 26 (35)
Reservoir To Power Flow Regulator 37 (50)
Return Pipe To Oil Tank On Power Flow Regulator 12 (16)
Wheel Bearing Unit On Wheel Carrier 74 (100)
INCH Lbs. (N.m)
Wheel Cylinder To Brake Backplate 88.5 (10)
(1) Tighten 7 mm bleed screw to 31.0-44.3 INCH Lbs. (3.5-5.0 N.m).

BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
Application In. (mm)
Front

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 58 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Disc Diameter 13.1 x 1.4 (356 x 36)

Minimum Thickness 1.35 (34.4)
Disc Diameter 13.1 x 1.2 (332 x 30)
Minimum Thickness 1.1 (28.4)
Parallelism .0004 (.01)
Radial Runout
Disc Installed .008 (.20)
Disc Removed .002 (.04)
Wear warning from residual lining .12 (3)
thickness
Rear
Nominal size (diameter x thickness) 12.8 x .8 (324 x 20)
Minimum Thickness .7 (18.4)
Nominal size (diameter x thickness) 12.8 x .5 (324 x 12)
Minimum Thickness .41 (10.4)
Parallelism .0004 (.01)
Radial Runout
Disc Installed .008 (.20)
Disc Removed .002 (.04)
Wear warning from residual lining .12 (3)
thickness

SPECIAL TOOLS

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 59 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 42: Identifying Allen Key (34 4 000)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 60 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 43: Identifying Bending Tool (34 5 100)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 61 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 44: Identifying Bit Insert (34 1 080)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 62 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 45: Identifying Brake Booster Tester (34 3 100)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 63 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 46: Identifying Brake Lining Measuring Gauge (34 1 260)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 64 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 47: Identifying Fixture (34 1 050)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 65 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 48: Identifying Removal & Installation Tool (33 2 110)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 66 © 2006 Mitchell Repair Information Company, LLC.
 2000 BMW X5
2000-06 BRAKES Disc - X5 (E53)

Fig. 49: Identifying Set of Tools (33 4 200)

Courtesy of BMW OF NORTH AMERICA, INC.

Microsoft
Sunday, June 20, 2010 9:29:36 AM Page 67 © 2006 Mitchell Repair Information Company, LLC.