I just replaced front brake pads on my '04 545i and I noticed that the top brake caliper guide bolt does not tighten down to its previous level, to the point where the rubber/plastic caps do not have enough clearance on rubber boot to stay on. The bottom brake caliper brake bolt seats fine and the rubber/plastic cap goes on fine. Anyone else had this issue before? Thanks in advance!

 

Remember - those two bolts are different lengths. Make sure you don't have them swapped by accident.

Also, be very careful with tightening them! I was tightening one to the book's "spec", and it ended up snapping on me leaving the tread inside the caliper, and nothing outside to grab it with. Not fun.

 

Thank you Ricapar! I will definitely check them and put some anti seize on the bolts this time.