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Re: cons...not as roomy and a slightly stiffer ride...

Sport package is the only way to go. Lower, stagered 18" wheels.

Re: Considering moving from 540 sport to 335i...

I have been debating the switch from an E39 to a 335. Just bought a new 335d. Thrilled with the grunt! Glad i did.Pick it up Saturday. They are hard to find. I was going to buy one from Sacremento dealer but buying a CA car it to much work.Found the right one in SLC.

Thx for the replies..commute about 3300 miles/mnth

..about 75% of that is open lane tollway/expressway driving :) ...something 540 excels at for sure!

Re: cons...not as roomy and a slightly stiffer ride...

Even the 328i will suit most people's needs for speed. 65 to 100 is no problem even in 6th gear. I get about 32 mpg's on the highway @75-80 mph, currently reading 25.2 combined. The SP is not so jarring either, but ofcourse mine came with 17's, I don't know about the 18's on the 335's. Don't forget though the run-flats on newer BMWs add to the harsher ride.

How long is your commute?

I moved from a 528i (E39) to our E36 for a 75 minute commute and really got tired of the jarring ride, especially from the SP suspension. First, I swapped the SP suspension to M3, but it was still too stiff for that commute. I picked up my 525i last Fall: What a relief, even though it too has an SP. I have only taken dealer shuttle rides in an E90, but it felt pretty stiff. So, you may have to adjust your expectations. . . Nothing is as comfortable for a long commute as a five series.
'03 525i Sapphire Blu/Grey, SP, Nav
'02 325it Orient Blu./Grey, SP, Nav
'01 325it Steel Blu./Blk (in salvage)
'98 323is Arctic Sil./Blk, SP
'95 M3 Cosmos Blk./Blk

Thanks guys... yeah I haven't driven one

yet but hope to get time in the next few weeks. I did have a 328is coupe back in the day :) and loved the suspension/ride. The 540 just kicks [Oops!] on long runs and goes from 65-100 mph with seemingly little effort. I love it and will miss it. I've owned a lot of cars and nothing has been better on those long trips. I still get 26+ mpg on the highway with it :) I think I'm going to make the move though it's only a matter of time. Appreciate the responses! Thanks!

Re: cons...not as roomy and a slightly stiffer ride...

I'm not too sure about "accelerate faster", as the V8's have plenty of torque and horsepower. The 335i is quicker in a 1/4 mile.

Ride quality is going to be the biggy; the 5's longer wheelbase gives it an advantage in quality/softness. You might consider the non-sport-package 335i if you think the sport-package is too stiff.

cons...not as roomy and a slightly stiffer ride...

pros...335i will handle better, accellerate faster and give a slightly stiffer ride. Do IT!
<a href="http://s131.photobucket.com/albums/p315/hoscarnag/roadflypix/?action=view&current=Loungesiggy.jpg" target="_blank"><img src="http://i131.photobucket.com/albums/p315/hoscarnag/roadflypix/Loungesiggy.jpg" border="0" alt="Photobucket"></a>

Considering moving from 540 sport to 335i...

my 540 has been a highway chomping monster for a long time... with 256,000 miles on it I'm considering something smaller as I mostly commute/drive solo..(and it seems like every repair lately is $1000+). Curious to see what the pros/cons of a change like this might be. TIA...