Just finished replacing starter
 

http://www.xoutpost.com/bmw-sav-foru...-e53-4-4l.html

First of all, big thanks to AquilaBMW. His write up was spot on. The only thing unnecessary was removal of plastic undercover. It can stay in place as it's only connected to stiffening plate with two 10mm bolts.

My symptoms were starter staying engaged for a second or two after engine starting producing nasty sound which probably would create more problems later.

Even though I'm pretty experienced, I made a stupid mistake of removing the wrong upper bolt. That added good 2 hours. The correct upper bolt is completely hidden from view and the wrong bolt is just above it and when you're father of 5 year old daughter who's checking every 5 minutes if I'm done, it was bound to happen.

The BMW prices for stiffening plate bolts and nuts have basically quadrupled so I ended up getting M10x60 and M10x70 bolts at local Ace. They were out of M10x50 which is perfect replacement for OEM M10x55, since Ace bolts are thinner at head and therefore identical in lengths.

Basically, 6 flanged M10x50 bolts , 6 nuts and 6 washers will run you about $25 vs $75+ at the dealer. Ace bolts and nuts are 10.9 grade as OEM but they actually look and feel even stronger.

I got Bosch remanufactured starter with 2 year warranty from RockAuto for $141 (+$65 for core) shipped. After returning core and paying for return shipping the total price will be around $155 which is about the best price anywhere at the moment.

The symptom is completely gone and now starter disengages immediately after start up.

Hopefully this helps somebody and again thanks to AquilaBMW.