E60 Chassis Dynamics

E60 Chassis Dynamics

Model: E60
Production: Start of Production MY 2004
Chassis Dynamics

System Desciption Topics


^ Understand E60 Front and Rear Suspension layout
^ Understand operation of DSC 8
^ Understand parking brake operation
^ Understand SPA operation

Front Axle





The double-joint spring strut axle with tension struts is essentially the same as the front axle of the E65. The complete front axle is made from aluminum. It has been possible to save on weight and space compared with the E39 thanks to the use of the reinforcement plate. The reinforcement plate ensures a high degree of transversal vehicle rigidity.
Axle alignment is performed at the tie rods. If necessary, the camber is corrected by removing the pin on the upper support bearing.
The car must not be driven without the reinforcement plate in place! The reinforcement plate ensures the transversal rigidity of the car and contributes in conjunction with the front aide carrier to the strength of the front aide.

Rear Axle





The rear axle carrier, the control arms and the swinging arms are made of aluminum. The concept is that of the Integral 4 rear axle. All the bearings used on the rear axle are rubber bearings. Tension struts serve to increase body rigidity.
The stabilizer bar is fitted behind the rear axle carrier. The ride level sensors have been moved forward.





Technical Data for Alignment

Suspension and Damping
Spring struts with coil springs and twin tube gas pressure dampers are used on the front and rear axles. The sports suspension available as an option is 15 mm lower at the front and rear axles compared with the standard suspension. The sports suspension has bee equipped with harder springs, sportier damper tuning and stiffer stabilizer bars.

Brakes
The E60 has a hydraulic dual circuit brake system with front/rear split. The electric precharging pump for the DSC function has been omitted. The 525i is fitted with conventional floating calipers on the front and rear axles. The 530i is fitted with floating caliper with frames on the front axle and conventional floating calipers on the rear axle. With the exception of the floating calipers on the 545i all caliper housing are made of aluminum.








The new lightweight brake rotors are used on the E60.The braking surface is made from grey cast iron, while the hubs are made from aluminum. The hubs are mated to the rotor using a series of rivets. The following configuration is used:
All brake discs are coated with geomet. M12 studs are used to bolt the wheel.

Pedals
The pedal bracket is a glass-fibre-reinforced molded plastic part. The brake and clutch pedals are mounted on axle shafts, which are also made of glass-fibre-reinforced plastic. These axle shafts are secured by retaining lugs in the axial direction in the bracket.

Notes for Service:
Because it is not always possible to remove axle shafts without damaging them, they must not be reused once they have been removed.
Because the pedal bracket/brake pedal connection is particularly critical to safety, the brake pedal is not to be removed on its own. The entire component must be replaced instead.