Checking the output flange on the rear transfer box

WARNING: This page does not describe the selected car, but rather 26 other vehicles, including the 2023 BMW M550i xDrive, 2023 BMW 540i xDrive, 2023 BMW 530i xDrive, 2023 BMW 530e xDrive, and 2022 BMW M550i xDrive. However, it is still accessible from the selected car via links, so may be relevant.

Preliminary work

Remove rear UNDERBODY PROTECTION .
Remove the tunnel connecting SUPPORT .
If installed: remove the right and left TORSION STRUT where required.
Remove complete EXHAUST SYSTEM .
Remove the HEAT SHIELDS .
Remove the RETAINING PLATES
Partially loosen the PROP SHAFT
Remove transmission CROSS-MEMBER .
Remove the output flange radial shaft SEAL (ATC 13-1).

NOTE: RISK OF DAMAGE
Damage to the transmission.
Damage to the transmission due to unapproved transmission oil.

Use only the approved TRANSMISSION OIL .
Check the transmission OIL LEVEL after completing the repair.

NOTE: TECHNICAL INFORMATION
Always replace the output flange with a new radial shaft seal.

Determine the thickness of the new shim before the installation of the output flange.
Determine and note dimension (A) of the old and new output flange.

Courtesy of BMW OF NORTH AMERICA, INC.

Determine and note dimension (B) of the old and new output flange.

Courtesy of BMW OF NORTH AMERICA, INC.

Determine the dimension (C) (= thickness of the shim) of the old shim.

Courtesy of BMW OF NORTH AMERICA, INC.

Calculate thickness of new shim:

Step 1 : (Dimension A. (previous output flange) + Dimension C. (previous shim) - dimension B (previous output flange)

Step 2 : Dimension A. (new output flange) -dimension B. (new output flange
Step 3 : Result step 1 - result step 2

Follow-up work

Install the output flange radial shaft SEAL (ATC 13-1).
Check/top up the transfer box OIL (active torque control 13-1).
Install transmission CROSS MEMBER .
Fasten the (partially removed) PROP SHAFT
Install the RETAINING PLATES .
Install the HEAT SHIELDS .
Install the complete EXHAUST SYSTEM .
If installed: install the right and left TORSION STRUT where required.
Install the tunnel connecting SUPPORTS .
Install the transmission side UNDERBODY PLANKING .
Install rear UNDERBODY PROTECTION .