Necessary preliminary tasks

WARNING: This page is about a different car, the 2012 BMW 328xi, 2011 BMW 328xi, 2010 BMW 328xi, and 2009 BMW 328xi. However, it is still accessible from the selected car via links, so may be relevant.

Remove OUTPUT SHAFT FROM REAR DIFFERENTIAL and tie back

Using a suitable screwdriver and a hammer (acting as a rest), force drive flange (1) off rear differential.

Installation:

Replaced deformed or damaged dust plates.

Insert drive flange and rotate until spline on flange meshes with teeth on differential bevel gear.

Press drive flange in further until circlip locates with an audible click.

Fig 1: Removing Flange From Rear Differential

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: High installation forces indicate that the spline teeth on the drive flange/differential bevel gear are damaged/deformed!
Check spline teeth, replaced damaged parts.

Install retaining ring (1).

Installation:

Clean shaft seal race on drive flange thoroughly.

Coat drive flange at contact face of shaft seal with approved rear differential oil. See REAR AXLE - OPERATING FLUIDS .

Fig 2: Identifying Retaining Ring

Courtesy of BMW OF NORTH AMERICA, INC.