Replace the rear axle final drive

Special tools required:

33 5 206
2 348 293
33 5 070
23 4 050
00 2 030
33 5 120
33 5 126
33 5 122
33 4 050
33 5 127

WARNING: Danger of injury!
33 5 206 Rear axle final drive must be lashed with tensioning strap to prevent it falling out when the output shafts are forced off.

CAUTION: After completing the repair, check the OIL LEVEL in the rear axle differential!
Use only the approved differential oil: BMW rear differential fluid MSP/A , BMW part number 83 22 2 365 988

Failure to comply with this instruction will result in serious damage to the rear axle differential.

After the running-in phase of 2000 km, during which the running-in instructions of new vehicles apply, an OIL CHANGE IN THE REAR AXLE DIFFERENTIAL is absolutely necessary!

CAUTION: Replacement of the sunk nut on the rear axle differential is mandatory!
Vehicles up to 07/2016:
Use new, non-precoated sunk nuts. Bond the recessed nut and propeller shaft with Loctite 648!
Vehicles with production dates from 07/2016 - 11/2017:
Use precoated recessed nuts! Do not further bond the recessed nuts with Loctite 648!

After the propeller shaft has been screwed into the rear axle differential, the hardening time must be observed!.

Hardening time:

Non-precoated recessed nuts (adhesive strip with Loctite): min. 3h
Precoated recessed nuts: min. 2h

The hardening time may be extended at lower temperatures!

Failure to comply with these instructions may cause serious damage!

Necessary preliminary work:

Remove RIGHT REAR WHEEL .
Remove EXHAUST SYSTEM .
Remove the BRACING STRUTS .
Remove rear propeller shaft heat shield

Removal:

F83 only:

Loosen screw (1).

Remove reinforcement bar (2).

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CAUTION: The propeller shaft and rear axle differential are mutually balanced. When installing, the propeller shaft must be bolted back onto the rear axle differential at the same position!
Failure to comply will result in humming and vibrations!

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Before loosening the propeller shaft:

Check that mark (1) on rear axle differential and mark (2) on propeller shaft are present.

Mark (1) present → propeller shaft can be loosened.

Mark (1) not present → transfer mark (2) from propeller shaft to dust plate (transfer white marker line on carbon pipe (propeller shaft) to dust plate of rear axle differential)!

CAUTION: The bi-hexagonal flange nut must not be used for bracing.

To unscrew the recessed nut, engage into gear and operate the parking brake!

Release sunk nut clockwise with the special tools 2 348 293 and 33 5 070.

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Hang up CRP propeller shaft (2) with a tensioning strap (3).

On removal of rear axle differential, sliding joint (1) must be pulled from input flange of rear axle differential.

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Remove RIGHT OUTPUT SHAFT .

Disconnect the plug connection (3) from the temperature sensor.

Release the cable clip (2) of the sensor cable (1) from the oil sump.

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Disconnect the plug connection (1) from the servomotor of the rear axle differential (2).

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Slacken nut (1).

Remove ground strap (2) from bolt.

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Place the special tool 23 4 050 onto the universal jack 00 2 030.

Support the rear axle differential with the special tool 23 4 050.

Secure the rear axle differential with tensioning strap (1) to special tool 23 4 050.

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CAUTION: The rear axle support must be lowered to disassemble and install the rear axle differential.
In order to prevent lowering of the rear axle support beyond the specified dimension, the originally installed screws of the rear axle support must be replaced by repair screws M12x1.5x115 (part number: 07 14 7 426 660).

It is essential to fit the repair screws M12x1.5x115 with washers 37x2.5 (part number: 31 33 6 776 760).

Undo screws (1) one after the other and replace by repair screws M12x1.5x115.

Lower rear axle support at rear by 35 mm.

During the lowering process, it is imperative to make sure that no adjacent components are damaged!

CAUTION: Risk of damage ! Lowering the rear axle support by more than a maximum of 40 mm may cause damage to the other components.

Screw in the repair screws so that the rear axle support is held in the lowered position by the repair screws.

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Loosen screw (1).

Remove vibration absorber (2).

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Special tools 33 5 120 and 33 5 126 must be inserted in all-round slot (1) on output shaft!

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Use special tool 33 5 120 with the moulded part 33 5 126 to press (in jolts) left output shaft by approx. 5 cm out of the rear axle final drive unit.

The thrust piece of the bolt 33 5 122 positioned against the rear axle final drive unit (see arrow in illustration).

Caution! Risk of damage!

Do not support thrust piece of screw 33 5 122 at oil sump.

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Loosen screw (1).

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Release screws (1 and 2).

Pull sliding joint (3) off input flange of rear axle differential.

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Lower the rear axle differential with special tools 33 4 050 and 00 2 030.

CAUTION: It is essential to make sure that the left output shaft does not collide with the rear axle support.
Protect output shaft against damage.

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Press front of final drive unit to the right.

Thread out left output shaft.

Lower rear axle differential with special tools 33 4 050 and 00 2 030.

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Installation:

CAUTION: Check dust plate (1) for damage, replace if necessary.
Coat contact surface (2) of output shaft with approved differential oil: BMW rear differential fluid MSP/A , BMW part number 83 22 2 365 988
High installation forces indicate that the output shaft spline teeth are damaged or deformed!
Check gearing and replaced parts if damaged.

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Position the rear axle differential on the rear axle support.

Guide left output shaft into rear axle differential!

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Replace screws (1 and 2).

Parts : Bolts

Insert screw (2) into holder before positioning rear axle differential on rear axle support.

CAUTION: Due to tight installation space, screw (2) can no longer be inserted into holder after positioning rear axle differential on rear axle support.

Pull sliding joint (3) back.

Raise rear axle differential until screws (1 and 2) can be screwed.

Tightening torque 33 17 2AZ .

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Replace screw (1).

Parts : Screw

Tighten screw (1).

Tightening torque 33 17 3AZ .

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Replace screw (1).

Parts : Screw

Position vibration absorber (2).

Tighten screw (1).

Tightening torque 33 17 4AZ .

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Lift the special tool 23 4 050 with the workshop jack 00 2 030 until the rear axle support is in contact with the body.

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CAUTION: The repair screws must be replaced by new original screws M12x1.5x60!

Undo repair screws (1) one after the other and replace by new original screws M12x1.5x60.

Parts : Bolts

Tighten down screws (1).

Tightening torque 33 33 1AZ .

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Remove tensioning strap (1).

Lower the special tool 23 4 050 with the universal jack 00 2 030 and set it aside.

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Clean adhesive residue from the thread (1) of the propeller shaft hub.

Clean and degrease hub teeth (2).

Clean and degrease axial contact surface (3).

CAUTION: Thread (1), propeller shaft hub (2) and axial contact surface (3) must not be contaminated with grease!

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Before fastening the propeller shaft to the rear axle differential:

Clean insert collar (1) on flange nut and gearing on bevel pinion (2) of all residues and degrease!

Top up insert collar (1) using grease Castrol Optitemp HAT LF1, BMW part number 83 23 0 417 754.

Clean and degrease axial contact surface (3).

CAUTION: Gearing (2) and contact surface (3) must not be contaminated with grease!

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CAUTION: Adhere without fail to the installation and screw-fastening sequence and joining time.
Installation sequence:

Join propeller shaft to transmission
Join propeller shaft to rear axle final drive

Screw-fastening sequence:

Flexible disc to transmission
Sunk nut on propeller shaft

Joining time using Loctite 648 applicable only for vehicles with production dates up to 07/2016:
After applying Loctite 648, the parts must be installed within 12 minutes!
Failure to comply with this instruction may result in detachment.

Use Loctite 648 (BMW part number 9 067 732) and evenly apply an even bead in this area (1) approximately 20 mm from the outside. The Loctite 648 must fill all tooth gaps uniformly to a length of approx. 5 mm.

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Align mark (1) on propeller shaft with mark (2) on rear axle differential dust plate.

Push propeller shaft on up to limit position of recessed nut.

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Screw recessed nut (2) by hand at least 2 thread turns onto propeller shaft (1).

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CAUTION: Only for vehicles with production dates up to 07/2016 with non-precoated recessed nuts:
Apply Loctite 648 to the thread (1) of the propeller shaft as close as possible to the sunk nut.

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CAUTION: The bi-hexagonal flange nut must not be used for bracing.
Failure to comply with this instruction may result in serious damage to the rear axle final drive.
To tighten sunk nut, engage a gear and operate parking brake!

Screw in sunk nut with special tools 2 348 293 and 33 5 070 (counter-clockwise, see direction of arrow in illustration) .

The sunk nut must be screwed into place within 5 minutes.

Tightening torque 26 11 3AZ .

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CAUTION: Ensure that screw connections are correct!
A - incorrectly screwed → thread start of propeller shaft must not be visible!
B - correctly screwed Distance between recessed nut and propeller shaft: 0 to max. 4 mm

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Remove tensioning strap (3).

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Special tool 33 5 127 must be mounted in the allround slot on output shaft.

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Drive in left output shaft with special tool 33 5 127 and a rubber mallet into the rear axle differential.

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Install RIGHT OUTPUT shaft

Position ground strap (2).

Tighten nut (1).

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Connect plug connection (1) at rear axle differential servomotor (2).

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Fasten cable clip (2) of sensor cable (1) on oil sump.

Connect plug connection (3) at temperature sensor.

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F83 only:

Position bracing strut.

Replace screw (1).

Parts: Screw

Tighten screw (1).

Tightening torque 33 32 15AZ .

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After installation:

Check the OIL LEVEL in the rear axle differential, correct if required
Install rear propeller shaft heat shield
Install the BRACING STRUTS .
Installing the COMPLETE EXHAUST SYSTEM .
Installing the REAR WHEEL ON THE RIGHT .
Perform START-UP .
Perform wheel alignment. Refer to CARRY OUT KINEMATICS DIAGNOSIS SYSTEM WHEEL ALIGNMENT WITH VEHICLE LOAD UP TO DESIGN POSITION or KINEMATICS DIAGNOSIS SYSTEM WHEEL ALIGNMENT WITH RIDE HEIGHT MEASUREMENT WITHOUT LOADING THE VEHICLE .