Replacing radial shaft seal for output flange

WARNING: This page is about a different car, the 2006 BMW X3, 2005 BMW X3, and 2004 BMW X3. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: After completing work, check OIL LEVEL and top up if necessary.
Use only approved GEAR OIL .

Necessary preliminary tasks:

Remove PROPELLER SHAFT .
Remove propeller shaft from transmission. Release center bearing. Tie propeller shaft to one side. These tasks are described in REMOVAL AND INSTALLATION OF PROPELLER SHAFT .

Release retaining ring (1).

Fig 1: Identifying Drive Flange And Special Tool (33 1 150)

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Installation note: Replace O-ring in output flange. Check that O-ring is in correct position.

Fig 2: Identifying O-Ring In Output Flange

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IMPORTANT: The propeller shaft may move when the output flange is pushed on. The retaining ring can thus no longer be fitted.

Installation notes:

Version: output shaft with mounting groove (1):

Push on output flange
Using 2 screwdrivers, press output flange downwards or output shaft (2) upwards until groove for retaining ring is completely visible.
Fit retaining ring.

Fig 3: Pressing Output Flange Downwards Or Output Shaft Upwards

Courtesy of BMW OF NORTH AMERICA, INC.

Version: transmission output shaft without mounting groove:

Support transfer case with a suitable sleeve (1) on transmission input shaft (2).
Push on output flange
Fit retaining ring.

Fig 4: Identifying Sleeve And Transmission Input Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Drive a hole into radial shaft seal (2) using a center punch (1) as shown in illustration.

IMPORTANT: Do not use a drill as drillings may result in transmission malfunction.

Fig 5: Identifying Radial Shaft Seal And Center Punch

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Screw in special tool 23 0 490 (puller). Drive out radial shaft seal (1) with impact weight (2).

Fig 6: Identifying Radial Shaft Seal, Impact Weight And Special Tool (23 0 490)

Courtesy of BMW OF NORTH AMERICA, INC.

Drive in radial shaft seal with special tool 27 1 400 (drift).

Fig 7: Identifying Special Tool (27 1 400)

Courtesy of BMW OF NORTH AMERICA, INC.

Reassemble the vehicle.

Check OIL LEVEL .

Check transmission for leaks.