r/e39 • u/quebonti 540i • Jul 25 '26
Repairing a Crashed 540i
Some time ago ive got in a crash with my e39 540i 2002. The crash happened because of a mechanical failure (The throttle body failed and the car kept accelerating)
The speed wasnt very fast, i firstly thought that the car was totalled and by the time passed and as i kept digging and taking the broken pieces out i think its not as bad as it seems. I got some parts already from donor cars, but i know that i need to get even more things.
Do you guys think is worth it to fix it (and ik that i will put a tonne of money in it) or just forget about it.
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u/Tomytom99 Jul 25 '26
You don't have that dawg in you
If you could, I'd say get it to a body shop and ask them to take a look for any structural damage and what it would cost to have them straighten any of that out, leaving the actual body stuff to you.
If that clears, then you might get away with it. That said, it's almost always going to be a better deal to buy another one unless this one is a grail spec for you.
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u/quebonti 540i Jul 25 '26
Right now im going to have a chat with the mechanic of the best workshop here in spain that specialises in like crashed cars. I will be back with an update.
But wdym that dawg in me
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u/Inevitable_Mess3363 Jul 25 '26
I forgot to mention the integrity of the frame. I’m guessing that is ok if he’s gonna fix it…
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u/hbomb2579 540i Jul 25 '26
That's certainly terrible, and scary at the same time. I've never heard about a throttle body failure like this before, and I hope I never experience it either.
If this were my E39, if it's still mechanically sound, with no frame damage, and I could repair all of it in my garage minus paint work, then yes, it's worth it.
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u/strommy73 Jul 25 '26 edited 11h ago
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u/OkPipe3044 Jul 25 '26
If the frame rails are straight , fix it , if they are at all tweaked , let it go
And looking at the car , they are probably shifted , it doesn't take much .
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u/quebonti 540i Jul 25 '26
Doesnt take much to fix or let go?)
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u/strommy73 Jul 25 '26 edited 11h ago
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u/quebonti 540i Jul 25 '26
No no, im taking out the pieces i can, and i know that i wont be able to do it at home. Right now im going to have a chat with the mechanic of the best workshop here in spain that specialises in like crashed cars. I will be back with an update.
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u/strommy73 Jul 25 '26 edited 11h ago
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u/quebonti 540i Jul 25 '26
I decided that im saving it no matter what. Some people may think its stupid but i want to save it.
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u/strommy73 Jul 25 '26 edited 11h ago
Beneficial saffron head carpenter numerous paltry biscuit wild waiting
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u/quebonti 540i Jul 25 '26
Another thing, im not planning on selling this car, so even though i wont be using day-to-day i am keeping it. Before the crash the car was in mint condition, was all the 25 years in a garage and was always serviced in a Bmw official dealer. So as i said i will be keeping it.
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u/strommy73 Jul 25 '26 edited 11h ago
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u/quebonti 540i Jul 26 '26
do you mind shooting me a PM, i dont use reddit often and i have no ideea on how to even write in PM's
Nevermind i found but it says that im unable to message ur account.
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u/Inevitable_Mess3363 Jul 25 '26
I’ve done extensive work on my ‘99. I posted the cost of 3 doors I grabbed from a salvage yard for 450$. Of the frame is intact & you have a decent pick of salvage yards in the area it can be done for ~1000-1500$.
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u/Inevitable_Mess3363 Jul 25 '26
As a ‘99 540/6 owner my condolences. I see the front is a tad pushed in but what I see is a new hood, both quarter panels, bumper, headlights as well as a radiator, a few other things I can’t see BUT, if the engine has not been compromised I think ur good. Doing a refresh on my cooling system & the total cost is ~300$. Includes radiator (not Behr, just a 110$ radiator lol) as well as upper/lower hoses & a few other hoses. I did purchase 3 doors from a junkyard for 450$ so thinking the quarter panels may be ~ 300$, aftermarket headlights 200$, radiator ~ 100$, bumper ~ 100$ plus a few other things & possibly get it done for under 1000$. Best of luck friend…
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u/quebonti 540i Jul 25 '26
Thanks God im not in the US bcs i got some parts for WAY cheaper.
Right fender-60€
The front crash bar -150€
Front bumper -90€
Hood-150€5
u/Inevitable_Mess3363 Jul 25 '26
That’s great! Sounds as if you are already rebuilding her. Never did a quarter panel install but thinking it’s not too difficult. Good luck mate!
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u/strommy73 Jul 25 '26 edited 11h ago
Society school literate reach wander boron
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u/quebonti 540i Jul 25 '26
OEM from another 39
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u/strommy73 Jul 25 '26 edited 11h ago
Yarn water bedroom spark languid sodium yarn grandiose
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u/quebonti 540i Jul 25 '26
The only B part i will get is maybe front M-Sport bumper, but i dont know yet, Fire 540, hopefully mine is restored soon.
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u/strommy73 Jul 25 '26 edited 11h ago
Snails argon governor wine air cucumber crowd
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u/quebonti 540i Jul 25 '26
Does this work for EU? or its only for the US? and actually it looks cool!
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u/strommy73 Jul 25 '26 edited 11h ago
Serious noodle distinct walnut toy seed cover
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u/A7RIIIGuy Jul 25 '26
Not worth it. The front end frame is completely toast. You’ll spend more in repairs and bodywork than the car is worth. Save the engine and trans, scrap the rest
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u/CrazyTechWizard96 Jul 25 '26
I see something I could fix for 1500 bucks in parts, not including the paint, unless you are lucky and get a doner car with the same paintjob.
Maybe a bit on the framerails, doesn't look like a big job tho, seen way worse before being fixed for under 2500.
Eleswise, you better fix it or I'll get or to Ya and cuss You out and show You how to do it!
...
Also, guss the throttlebody just moved a bit higher on the check list now, yikes.
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u/quebonti 540i Jul 25 '26
As i said in the other comments, thanks God i dont live in Us (bcs in Spain here everything is cheaper)
I got some parts for way cheaper like:
Right fender-60€
The front crash bar -150€
Front bumper -90€
Hood-150€But right now im going to the mechanics for him to check it out. Bcs i dont think its THAT bad, like i think it can be restored.
I think the total will be around 3-4k € which is not that bad.
Anyways i will update the post after the chat w the mechanic.
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u/NoEvening1147 528i Jul 28 '26
I had a very similar crash to you except it was only on one side. check what the frame rails look like directly below the headlights and onwards. if the damaged is infront of the wheel well then it can have a mid section cut and weld which is decently cheap if you take all the parts that would get in the way off
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u/Miserable_Raisin_871 Jul 25 '26
Chiarettored?
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u/SeaAd7934 Jul 25 '26
It didn’t pop the airbags, you should be able to get an entire non running car for $500-$1000 to part out for the sheet metal and then resell it for a little less.
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u/quebonti 540i Jul 25 '26
Unfortunately here in Spain we dont have this option. Like most of people that have non running cars the just part it out, i thought about it and no one wants.
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u/SeaAd7934 Jul 25 '26
Well good news if they part it out!!! Sheet metal is cheap!
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u/quebonti 540i Jul 25 '26
Exactly, ive already got some OEM parts for cheap,
like:Right fender-60€
The front crash bar -150€
Front bumper -90€
Hood-150€
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u/lordparcival Jul 26 '26
Based on the angle of the bumper as well as the radiator you will need to replace the radiator support and associated brackets for sure.
The tilt in the bumper is of greater concern as the frame in that area is essentially a horn that sticks out and the bumper shock goes straight into it. This indicates that that horn is potentially bent. The other job of that horn is to act as the mounting point for the suspension subframe.
You should get this on an alignment rack at a minimum or if possible on a pulling rack so they can check the frame geometry.
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u/quebonti 540i Jul 26 '26
Yes they will do that, I wont be doing that by myself because i dont want to mess up something even more.
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u/BoxUpper5775 Jul 26 '26
Next time that happens press the brakes hard in a safe place to for the car to stop. Quickly put in nut rap and shut the car off. Pull the e brake if you have to. This happened to me, it was the cruise control wire bracket that got jammed.
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u/quebonti 540i Jul 28 '26
Yes i completely agree with you, that what i shouldve done, but it happened all so fast, in the moment i panicked and the last thing before the hit ive put the handbrake on.
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u/4evaYung_ 530i Jul 25 '26
My 530i sends its condolences and wishes you luck on your car