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3-Series (E36) Chat relating to the BMW 3-Series from 1992-1999. Autodoodad Specific models include: BMW 316i, BMW 318i, BMW 318iS/ti, BMW 320, BMW 323, BMW 320, BMW 324, BMW 325, BMW 328. is the premier BMW Forum on the internet. Registered Users do not see the above ads.
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Old 08-10-2004, 02:41 PM   #1 (permalink)
Join Date: May 2004
Posts: 11
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The first part of the story. E36 325i, 160000 miles. The brake wear indicator had come on. I replaced the brake disks, pads, sensors and fluid. I was bleeding the old fluid out when I THOUGHT I sucked some air into the system. I bled and bled and bled the system but still had a really mushy pedal. I took it to the dealer for them to bleed. Still no help. They said it was a bad master cylinder. Still no better. They said some of the master cylinder seal had plugged up the ABS unit. I decided to use the sense God gave me, pulled the ABS unit out, disassembled it, found NO dirt or bad parts of any description and put it back in. Still no better after 20 bleedings (almost 3 gallons of brake fluid).

Now, for the conclusion of our story. I wrote a letter to the service manager about their shop being a bunch of expensive parts replacers and, after no response from him, to the general manager of the dealership. Soon after, from the service adviser, “Bring your car back in (90 miles) and we’ll put our best man on it.” Got a new 325i loaner for a couple of weeks. It turned out that, in installing the front pads, one of the steel fingers that hold the pad to the piston had missed the hole in the piston and pushed out between the pad and the piston, creating a gap between BOTH front pistons and their respective pads. So, every time I applied the brakes, I not only had to close the gap between the 8 pads and 4 disks, but also two additional gaps between BOTH front brake pistons and the pads attached to them. This caused the increased brake pedal travel and mushy feel. There was also a rattle that they traced to a loose rear pad. I was sufficiently embarrassed about my part in this but unhappy that the dealer had so much trouble (at my expense, of course) solving a relatively simple problem.

The upside: I now have brakes that work properly and went ahead with purchase of an ’04 M3.

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Old 08-10-2004, 02:46 PM   #2 (permalink)
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Glad to hear it was fixed. Hope they didn't charge you too much for that.
Kevin (President TBEA)

"WAAAAAAARRRRRIORS, come out to plaaaaay."
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Old 08-10-2004, 03:29 PM   #3 (permalink)
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$1100 for the new master cylinder and a new right front control arm that was supposedly the cause of the rattle. They didn't charge me for the subsequent work to correct their first missteps. This included a new right rear shock and upper shock mount to correct the rattle. The whole experience gave me pause about buying a new BMW because, if they can't fix a 92 325i how could I expect them to repair a 04 or 05 M3? But I love BMW. The technician that made the first two astute diagnoses (master cylinder for the brakes and control arm for the rattle) supposedly left the dealership. Time for a followup letter to the GM.
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