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Thread: 2004 545i Muffler Delete

  1. #1
    Join Date
    Nov 2016
    Location
    New Zealand
    Posts
    18
    My Cars
    BMW 525i E39 2001

    Cool 2004 545i Muffler Delete

    Hi All,

    I live in a country where it's fine and dandy to remove the rear muffler, and it's what I plan on doing to let some sound out. It's legal to remove cats here also, but apparently the E60 throws O2 sensor errors if you do, and it's not the best for the environment so i'll just stick with the muffler.

    Just had a question, I've seen mufflers for this model in a few different shapes and sizes, and was hoping someone could explain a little bit about how best the muffler should be removed. I've attached a photo as below for how underneath my E60 looks. Could you remove just one of the mufflers (marked red) and leave the other (marked red) intact for a bit more sound, or is it best to remove the entire thing from where the blue arrow is? Could someone please explain why the muffler is designed this way in the first place?

    Untitled.jpg

    Any other suggestions/info is much appreciated!
    Thanks in advance all.

  2. #2
    Join Date
    Jun 2008
    Location
    Halifax, Nova Scotia, Can
    Posts
    211
    My Cars
    2004 E60 545i
    Can’t really answer the muffler question but have done this myself and it improves your idle rumble some....and if you remove the bottom muffler in your pic you should do this also, as the flap is in the top muffler pipe
    https://5series.net/forums/diy-do-yo...en-mod-133090/
    or this
    https://www.bimmerfest.com/forums/sh...t=muffler+flap
    Last edited by cmyachtie; 09-24-2018 at 07:19 AM.
    ">'85 Mlite E30, '98 E36, 1998 528i, 5 spd manual, black on black, sold in 2012 and still going past 350Kkms, now MYSTIC Blue 2004 545i, 6 spd Steptr., Adaptive steering and Xenons, Anti dazzle mirrors. Aux+Belt-Chime+Dig speedo+iDrive discl. 2007 TCU+BT Coded+Sure BT Board

  3. #3
    Join Date
    Nov 2016
    Location
    New Zealand
    Posts
    18
    My Cars
    BMW 525i E39 2001
    Quote Originally Posted by cmyachtie View Post
    Can’t really answer the muffler question but have done this myself and it improves your idle rumble some....and if you remove the bottom muffler in your pic you should do this also, as the flap is in the top muffler pipe
    https://5series.net/forums/diy-do-yo...en-mod-133090/
    or this
    https://www.bimmerfest.com/forums/sh...t=muffler+flap

    Thanks for the info! But more looking just to remove muffler rather than anything else.

  4. #4
    Join Date
    Feb 2010
    Location
    Atlantic Beach, Fl
    Posts
    502
    My Cars
    81,e21 orig ownr&05,e60
    I have to agree with cmyachtie on this. First looking at the flap controller override option as the German engineers took great effort to design the exhaust system for maximum flow with just the right backpressure to deliver maximum performance. Overriding the flap will make it sound more aggressive.

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