Brakes, Rust and More Rust!

Discussion in '5 Series' started by Peter, Sep 10, 2019.

  1. Peter
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    Peter WARLORD Site Supporter

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    The 535i had a brake issue flagged up at the Vehicle Health Check, back in July, "Corrosion on NSR inner disc face, requires replacement". MOT was OK, no advisory.

    Brakes were working fine, but knew they would soon need replacing. Already had the brake parts waiting tor fitting. Had sourced the parts on one of Europarts mega discount weekends, end of last year
    .
    Brembo Rear Brakes 800.JPG

    Last couple of weeks, after lots of wet weather, have noticed a bit of a strange feel to gentle braking and also noticed some pulsing in the pedal on harder braking. Decided today (first one available) was the time to get on with the job.

    This is what I found. :eek: Outside was fine. When I told my son, last evening, I was replacing the rear discs, he asked "why?" as the discs look fine.

    Rusty Rear Disc 800.JPG

    No wonder there was bit of an erratic slowing feel, and the petal pulse. What has surprised me, while knowing how the wet gets at brakes up here, is how quickly braking had changed from being smooth to telling me there was a bad corrosion issue.

    There were a tricky few minutes when ensuring all the bolts, particularly the parking brake actuator bolts would unscrew without losing the Torx drive. (Was relying on the mechanical rewind with the actuator off). A lot of rust and corrosion about. All went well, by patiently checking and cleaning all the parts, ensuring the Torx bit could get maximum depth, before attempting any torque being added. So pleased when the forth one 'cracked' a release.

    Peter
     
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  2. Kev2005
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    Kev2005 WARLORD Site Supporter Good Egg

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    wow, how long had these been on your car, out of interest? I've been told my brake pads are at 8mm, tyres at 6mm so all ok but got me wondering if they really are now :) Car will be 4 years old next year.

    Kev
     
  3. Peter
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    Peter WARLORD Site Supporter

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    Rear brakes were original, coming up 58k miles at over 8-years old. Pads are about 4 - 5mm. Rear brakes work harder on the 5-series and actually wear quicker than the fronts. I had thought I'd have to replace sooner than this, (hence getting the new parts last year), but as the pads were holding up and there wasn't any judder, I had held back.

    I had to replace the front discs and pads a couple of years back, at about 42k miles, as the discs were so badly corroded. Pads were still about 10mm.

    This topic reminds me I was in the process of buying the 535i 7-years ago, this very week. Will soon have to write up the last few thousand miles use and update the spreadsheet, to see the true cost of running an 8-year old car. I do know this year has cost a bit more on maintenance.

    Peter
     
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  4. Kev2005
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    Kev2005 WARLORD Site Supporter Good Egg

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    Interest @Peter, what size are the pads new? My garage has been telling me the pads are 8mm all round I think every time it goes in and I can re-assure, i definitely do use the brake pedal so i'm puzzled why they are always the same. I don't brake hard, unless i have to for any reason but they do certainly get used.

    Sounds like i got a little way to go yet, my cars around 22-23k miles atm.

    Looking forward to the write up.

    Kev
     
  5. a.s.uk
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    a.s.uk

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    I think I’ve got the same issue on my van Peter... discs and pads look brill.., but I fear it’s the inside face that’s making the noise on the rear left... only wheel removal will confirm soon...


    Sent from my iPhone using Tapatalk
     
  6. Peter
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    Peter WARLORD Site Supporter

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    Garage should be giving a pretty accurate reading, they have a tool to read the pad thickness. Mine were recorded on the VHC as 12mm front and 5mm rear, back in July. That is what I calculated, when checking ahead of the MOT.

    New pads are something like 14mm front and 12mm rear. Never thought to check the exact pad thickness of the new rear pads this morning, but definitely around the 12mm thickness.

    Regarding the write up, need to think about the last year, or so, assess the highs and lows of ownership. Couple of possible issues currently, had a side view camera error come up last week. (n) Today... noticed a very damp driver's door sill plate when I opened the car, could be another vapour barrier leak developing. :( Didn't have time to really investigate, just dried it off and hope tonight's rain doesn't do the same.

    Peter
     

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