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Old 10-06-2017, 01:27 PM   #1
wc123wc
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Join Date: Sep 2011
Location: Toronto
Posts: 260
E39 Trunk Rattle [Solved]



I hope this write-up will help someone.

My trunk's dampers were worn out (very weak) so the trunk used to slam pretty hard, this caused few problems including breaking the tool box screw; I had to replace this screw 3-4 times in one year. One way to solve the failure of the tool box screw is to drill it and put a long screw through it--this will make the screw much stronger. But this will not change the fact the dampers need replacing.

So I replaced the dampers with an aftermarket dampers (some European brand, I can't remember the name). With the aftermarket dampers, the trunk was still closing pretty hard (but not as hard as with the worn out OEM dampers). Also, because the aftermaket dampers are new they are pretty strong when they open the trunk causing a rattle at the top when the trunk is fully opened.

I solved the closing hard problem by using springs (you will have to get pretty strong springs that can pass over the head of the damper arm), and you will have to cut the spring down to your desired closing force.
I also put washers between the spring and the damper's end cap to prevent the end cap from being damaged because it's made of relatively thin plastic.

I solved the rattle when the trunk is fully opened by putting a spacer between the trunk's linkages. This worked great. Now the trunk makes no noise and it feels and sounds like it should feel and sound!

For the washer and spacer I used a very tough rubber material used as a belt for manufacturing machines. For the washer I used 2 layers, and for the spacer I used 3 layers of this material. Other material and thickness can work but they have to be strong material (not the generic flimsy rubber sheets).

Good luck!
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Old 10-06-2017, 07:15 PM   #2
kenmar
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Join Date: Apr 2005
Location: Toronto
Posts: 415
The toolbox problem plagued my E36 for years to the day I sold it. Same BMW generation, so same design problem. Since the E9x cars, BMWs no longer have toolboxes because the accountants did away with both the spare tire and the tools, but I think I will deploy your spring concept on my back screen door because it makes very annoying rattles whenever it closes even though the damper is new
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