In total, the job took 4 hours but I spread it out over 2 days because of interruptions, family, life and of course going out to buy tools. I’ll talk more about tools shortly because having the right tools is critical to completing this job.
I called a shop that I trust (Bavarian Motorsport in Milpitas, CA) and was quoted ~$200 for doing this job if I got stuck. I presume that price would be labor only and require my parts. It was reassuring to have a fallback option if things went wrong. That is a little less than the cost of the special BMW tools so if your local shop is as cheap you might consider just having them do it for you. My motivation for doing this job myself, besides just fixing my sagging cargo hatch, was to survey the condition of this area and make additional repairs. As evidenced by broken and missing trim bits I could tell that someone had worked in this area at some time the car’s past and I wanted to take stock of and replace whatever was missing.
In addition to replacing a half dozen trims I also took the opportunity to clean all the trunk gutters, find some important places where screws were missing, replaced some broken lights, fixed one of the reading light switches and cleaned some spots the kids left on the headliner. These kinds of “while you’re at it” tasks are exactly why I like to do things myself.
If you’re planning similar improvements you should order any obviously broken or cracking parts well in advance as I found that most of what I needed was back ordered from Germany for 3-5 weeks. Apologies in advance for blurry, low light photos but that’s all I got.
The DIY I followed is posted on Bimmerfest and has been supplemented with some scans from the e39 Bentley service manual. The DIY is brief but actually quite accurate. Where it falls short is on those ever helpful details that give the novice the courage and smarts needed to actually do the job. Hopefully I can fill in the blanks below.
I replaced only the tailgate struts, BMW part number 51248220072 (see RealOEM for diagram). The dampers for the glass lid of my car are fine so I did not replace them. For the sake of cost and time I elected to do the job without the special BMW tools and everyone seems to agree that for the hatch struts the special tool is not required. However, a long and thin pry bar is absolutely required! More on that tool later.
If you’re interested, the special tools are well referenced in this for sale thread and photo set. If you wanted to replace the glass struts it’s possible to fabricate a tool from PVC pipe instead of buying the BMW tool. I could only find this tool described in vague terms so I’m on no help to you on that topic.
The toolset is BMW part number 83 30 0 492 604.
The toolset consists of 3 pieces:
5 12 153 Plastic Protector (small sheet of plastic)
5 12 152 Windows Strut Tool (aluminum tube)
5 12 151 Tailgate Strut Tool (aluminum bar with collar and fulcrum pin)
16″ Large Flat Screwdriver
24″ Harbor Freight Pry Bar with Handle
Metric Hex Wrenches
Trim Removal Tools
Flat Micro Screwdriver
Note: It’s possible to do this without removing the rear pillars and headliner. If you have the BMW tool or are able to use a screwdriver to pop the struts off their ball connectors without damaging the car then you can skip all of those steps.
For the e36 I ordered what should be a complete kit. This is not a top-of-the-line kit and the price reflects that; less than $30 for everything. Unfortunately my kit was short 2 bulbs so I used and extra LEDs I had lying around. I didn’t feel like wasting time taking it up with the vendor.
Some of the light panels come off with finger pressure but most will require some help from either a screwdriver or a trim removal tool. Generally the Bimmian guide is accurate. A few notes:
To solve the license plate light issue I decided to gamble on some top-of-the-line lights. I say gamble because no one likes it when expensive parts generate errors. I ordered the WeissLicht LED License Plate Illumination Upgrade from JLeviSW which is the same as Bimmian. I ordered the upgrade for the e36 M3 and our e39 touring. The lights appear well made and are complete housings and lenses, not just bulbs.
The lights were installed on the e36 first. I noticed that the connector plugs into the back of the LED housing instead of the side like OEM. This reduces the slack in the wire but is not a problem.
If you have OEM lights you may find that the new lights are a little loose: this isn’t a fitment issue, it’s just that the rubber seal on your old lights was probably stuck to the car creating the illusion of better fit.
The lights are held on more but the trunk handle than anything else, so once the handle is re-installed fitment should not be an issue.
It’s very important with these kits to install and test right away: warranty is usually 30-90 days but if you want to claim a warranty on a DOA part and save shipping costs you usually need to report it within 5 days of receipt. Unfortunately one of the lights has a short in it, but thankfully I just received these 2 days ago.
Until I get a replacement I’ll have one really bright light and one dim one.
I also installed the e39 version for our 2000 540i touring. They look great but fitment was difficult: the left side light kept crushing the bulb contacts which required some adjustment (bending) until they would contact properly.
These aren’t cheap but I got one in used condition for less than $100 from an eBay seller. Then I discovered that the adjusters were broken (the beams could not be aimed) and decided that a total aftermarket replacement was the way to go.
I ordered lights from DDM Tuning but while reading about the install process I learned that I could get better, easier to install lights for a little more money. Unfortunately I’d already tried to install the lights and was committed. I went to DDMTuning based on out dated product reviews and because I’d dealt with them previously. Next time I will definitely shop and compare more thoroughly.
The challenges to this install are:
Supposedly two pipes such as those used for plumbing can be used to bend the AC low side tube, but I was able to pick up a tool at Harbor Freight for $5 that proved effective.
Install took about 3 hours but would have taken less time if we’d had the correct turn signal bulbs before starting. The new lights (sans Angel Eye functions) are finally installed thanks to my buddy Ryan Rich who I must confess did most of the work.
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