Replacing the oil filler cap on the rear axle differential (AWD) (X2 xDrive 28i 2018-2023, X2 M35i 2019-2022)

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Special tools required:

0 496 080 (33 5 206)
0 496 080
11 4 471
11 4 472
2 460 340
F405 AC
A4CF405

WARNING: DANGER OF POISONING if oil is ingested/absorbed through the skin!
RISK OF INJURY if oil comes into contact with eyes and skin!

CAUTION: Risk of damage!
Failure to observe the oil specifications leads to serious damage to the hang-on clutch!

Use only the APPROVED OIL (see applicable BMW parts catalogue) for the hang-on clutch.
The oil to be filled must be at least at the room temperature (greater than 18°)
Adhere exactly to the oil capacity

CAUTION: Risk of damage!
Failure to observe the oil filling/draining leads to serious damage to the hang-on clutch!

To ensure correct oil filling of the hang-on clutch, the oil balance of the hang-on clutch must be completely drained before filling (remove the hang-on clutch and swivel the differential down).
To ensure correct oil filling of the hang-on clutch, the differential must always be swivelled down, even when oil is being filled.
The oil filler plug on the reservoir cap is not a fill level control screw!

Necessary preliminary work:

Refer to REMOVING COMPLETE EXHAUST SYSTEM .
Refer to REMOVING THE LEFT-HAND TORSION STRUT .
Refer to REMOVING HEAT SHIELD AT REAR .
Refer to REMOVING AND TYING BACK PROPELLER SHAFT ON REAR AXLE FINAL DRIVE .

Removal:

Unfasten screws (1).

Remove cover (2).

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Disconnect plug (2).

Loosen the connector (1) and loosen the cable (3) from the control unit holder.

Unfasten screws (4).

Remove control unit (5) together with bracket.

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Unfasten screws (1).

Remove the longitudinal torque distribution control unit (2) from the bracket (3).

Loosen the cable from the bracket (3).

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CAUTION: Danger of injury!

Check the tensioning strap for visible damage before each use.
Do not install the tensioning belt in a twisted manner.

Risk of damage!

Non-compliance may lead to damage to the output shafts/dust plates .

The tensioning belt must not touch the dust plate of the output shaft .
The tensioning belt must not be in contact with the gaiter on the output shaft .

Before releasing the rear axle differential, secure the rear axle differential with the tensioning belt 0 496 080 (33 5 206), or hook it.

Thread the tensioning belt 0 496 080 between the body, cross-member (1) and rear axle support (2).

Guide the tensioning belt 0 496 080 around the output shaft, connect and stretch both the ends.

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Only release the screws (1).

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Support rear axle differential (1) with universal jack (2).

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Release screw (1) of rear axle differential.

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Release the screws (1) from the differential cross member at the rear axle differential.

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CAUTION: Risk of damage!
Non-compliance may lead to damage to the output shafts/dust plates.

The tensioning belt must not touch the dust plate of the output shaft.
The tensioning belt must not be in contact with the gaiter on the output shaft.

Lower the differential with universal jack.

Rear axle differential maximum 22-27 cm (distance from the body to the center of the output shaft).

Adjust the length of the tensioning belt accordingly.

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Remove the universal jack and swivel/tilt the rear axle differential downwards.

Release the oil filler plug (1) on the oil expansion tank.

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Recycling:

Catch and dispose of escaping differential oil.

Observe country-specific waste disposal regulations.

Place oil drip tray under the rear axle differential.

Release the screws (1) on the hang-on clutch (2).

Pull the hang-on clutch (2) downwards out of the clutch housing.

Let the oil drain completely from the differential housing.

Turn the hang-on clutch through 360° spherically so that all of the oil (especially from the pump suction chamber) runs out.

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Unfasten screws (1).

Remove the oil filler cap (2).

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CAUTION: Do not use any metal-cutting tools (e.g. emery cloth).

Clean the sealing surface (1) on the rear axle differential (2).

If necessary, remove any surface sealing compound residue using special tool 11 4 471 or 11 4 472 .

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Installation note:

The sealing surfaces on the oil filler cap and at the rear axle differential must be free from oil, grease and cleaning agent.

Installation:

Apply Loctite 5970 surface sealing compound (see applicable BMW parts catalogue) in this area (1) on the oil filler cap (2).

Installation note:

Make sure that the sealing bead runs along the inner edge.

After having applied the surface sealing compound the oil filler cap must be installed in approximately 10 minutes.

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Position the oil filler cap (2).

Tighten down screws (1).

Tightening torque 33 11 3AZ .

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Coat sealing ring (1) with oil.

Installation note:

Replace sealing ring (1).

Parts: Sealing ring

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Insert the hang-on clutch into the clutch housing.

Pull in the hang-on clutch by evenly tightening the screws (1) crosswise.

Tighten down screws (1).

Tightening torque 33 10 1AZ .

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CAUTION: Risk of damage!
Failure to observe the oil specifications leads to serious damage to the hang-on clutch!

Only use the APPROVED OIL (see applicable BMW parts catalogue) for the hang-on clutch.
The oil to be filled must be at least at the room temperature (greater than 18°)
Adhere exactly to the OIL CAPACITY .

Installation note:

It is imperative to ensure that there is no air in the hose when topping up a defined (measured) oil quantity .

Use special tool 2 460 340 for topping up.

When topping up a defined (measured) oil quantity, first fill hose (1) with oil. To do this, connect an adapter (2).

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Download video

NOTE: The training video illustrates the methodology for the rear axle differential oil change using the oil spray special tool.
The training video does not replace the repair instructions.
The training video is not subject to the update service.
We can assume no liability for printing errors or inaccuracies in this service information and reserve the right to introduce technical modifications at any time.

Screw the special tool F405 AC in for oil spray on the oil reservoir cap.

Tightening torque: maximum 2 Nm