aja540i

57 minutes ago, Twistee said:

E39's are famous for being lightweight, I'm sure you would have walked it off  Glad the story ended the way it did  rather than you bench pressing the wagon. Must almost be ready to sort the exhaust and enjoy the new velvety ride.

It was on ramps at the time but if I had my arm in a different place it might have involved a trip to A & E!!

All back together now, test drive was ok but I have  a warning light for the SLS, code comes up as left side height sensor so I might have to swap it out for a spare and see if that fixes it! Also sounds like it has an exhaust leak now so I might have to chuck a new gasket in it.

Had a bit of a moment when one of the air spring couplers popped off and dropped the car about 60mm while I was under it! I like to think I shat myself with dignity!! 😀

Replacement clip found in a box of bits, fitted and coupler replaced, seems all good now so back under I go.....

Once by the previous owner, Monroe OEM spec. Not great, but certainly not the worst.

Ride height sensors back in, wheel speed sensors back in, brake calipers bolted up, sway bar back in, next up tighten the driveshaft bolts, put wheels back on, put the car on ramps and tighten all the suspension bolts, then chuck the exhaust back on!!

Should be all good for a wheel alignment booked for tomorrow morning, I have to say I am looking forward to driving an E39 touring with mostly refreshed suspension again, its been a while!

Then, 1500 km round trip to visit family next week, towing a trailer with a dog kennel on it! Kind of a "what will break next" roulette wheel.🤔

Rain didn't happen so subframe went back in, mostly done, just a few minor details like the brakes to bolt back up!!

Then hoping I can get a wheel alignment over the weekend!

Sub frame reassembled and ready to go back in, so tomorrow night will be;

Re-fit handbrake cables, lift subframe into place, bolt up driveshaft, bolt up subframe, attach air springs, attach sway bar, attach exhaust,  attach ride height sensors, attach brake calipers, put wheels on, put car on ramps and bounce it up and down, tighten suspension bolts, adjust handbrake, do a skid! Or it will be raining so I will watch some old project Binky on you tube.......

4 new Meyle HD subframe bushes in, unfortunately that concludes the "spare time" portion of my Saturday!

Let me know how you get on with your "worlds fastest LPG powered station wagon" record attempt!!

If I want to feel good about mine I just go for a drive in it, still makes me smile every time!

On mine it is the surround that holds the number plate, if you pull the outer layer of the surround off the number plate will fall out and you can unscrew the surround from the car.

Its a BMW supplied plate surround and its actually quite flimsy and doesn't fit particularly well!!

All 4 bushes out, no dramas! Also more shiny parts....

Did you provide the purchaser with a written guarantee when you sold him the car? If you did then honor the terms of the guarantee. If you didn't then he has no right to come to you asking for money for repairs, UNLESS YOU DELIBERATELY MISLED HIM about the state of the vehicle, and I don't  believe you did!

Feel free to suggest he researches his rights under the consumer guarantees act.

also, shiny new parts....

So far, so good! 2 bushes out with no drama.  A little bit of heat and some gentle persuasion, and in the fluke of the decade I found a piece of aluminium from the leg of an old computer desk that was a perfect fit for the size of the bush and even had an indent in the center the correct size to push them out with!!

I took the opportunity to remind my wife that I am a genius for keeping everything that " looks like it might be useful someday"

All apart, water blasted 24 years of experience off the subframe, everything else will get a clean up as well, time to order some parts.....

Both of the sway bar links fell apart, so they will be getting replaced as well!

Most of the bits unbolted now, bushes are absolutely knackered!

hand brake cables disconnected, driveshaft unbolted, subframe bolts out and hey presto!

Exhaust is off with a little help from my friends..

The only thing  more infuriating than the look of that grille is the fact that it doesn't even need a grille!

A bit of heat and some swearing will probably be enough, if not I have various sizes of angle grinders...

I assumed it was a resonator of some kind, but it could have been a cat/ dpf of some kind ( if old diesels had cats?)

Its not a major problem as its just a couple of quite rusty bolts to the turbo, what could go wrong? 

something has been cut out of the front and a straight pipe welded in, not sure what was there originally.

How much did the dealer quote to do the work?

Brake calipers off, ride height sensors, ABS sensors, lower shock bolts all out, one side down, one to go. I think the exhaust is going to be the biggest hassle as it is one piece from the muffler to the turbo!