31 60 535 Replacing Both Gaiters Of Output Shaft On Left Or Right

WARNING: This page is about a different variant/trim than selected.

Special tools required:

00 5 500
11 8 310
31 5 200
32 1 260

NOTE: Output shaft removed

IMPORTANT: Repair must not be carried out by way of the inner joint! Do not press off or disassemble wheel-side joint.

The transmission-side joint may be bent by max. 18° and the wheel-side joint by max. 45°!

Remove all traces of old grease from inner joint, wipe out old grease in outer joint.

Only use dry, clean cloth free of grease and lint for cleaning!

Visible soiling of joints (e.g. by water or dirt) will cause premature failure!

IMPORTANT: Always use plastic vice jaw protectors when working with a vice!
Tensioning straps are not to be reused!

Clean output shaft and grip in vice.

Release clamping bands (1).

Detach housing (2) and clean carefully.

Fig 1: Identifying Clamping Bands And Housing

Courtesy of BMW OF NORTH AMERICA, INC.

Remove circlip (1).

Fig 2: Identifying Snap Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Pull tripod star (1) off output shaft with special tool 11 8 310 and clean carefully.

Fig 3: Pulling Tripod Star Of Output Shaft Using Special Tool (11 8 310)

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Remove all traces of old grease. Old gaiter must not be reused!

Detach gaiter (1) of transmission-side joint and clean output shaft carefully.

Fig 4: Identifying Gaiter

Courtesy of BMW OF NORTH AMERICA, INC.

Removing outer joint gaiter:

IMPORTANT: The wheel-side constant-velocity joint is pressed on and secured with a snap ring. Do not press off or disassemble.
Failure to comply with this instruction will result in damage to the constant velocity joint.

Mark axial position (1) of gaiter (2) to wheel-side joint (4).

Release clamping bands (3).

Detach gaiter (2) of wheel-side joint.

Wipe accessible areas of hinge (4) with a clean and fluff-free cloth.

Fig 5: Identifying Axial Position Mark Of Gaiter To Wheel-Side Joint And Clamping Band

Courtesy of BMW OF NORTH AMERICA, INC.

Installing outer joint gaiter:

IMPORTANT: The wheel-side joint must not be repacked with more than 65 g of grease.
Only use grease from the repair kit or as specified in the BMW Electronic Parts Catalogue!
During assembly, the sealing surfaces on the gaiter and joint must be clean, dry and free of grease!

Slide new gaiter (1) onto output shaft and fill with lubricating grease from repair kit.

NOTE: The sealing surfaces (2) inside the gaiter and the groove on the constant-velocity joint must be dry, clean and free from grease.

Push filled gaiter together with infinitely variable jubilee clip dia. 85.5 mm on to wheel-side joint.

Ensure the gaiter snaps into the groove in the joint and is aligned with the axial marks.

Position a new infinitely variable jubilee clip dia. 85.5 mm in the groove for the gaiter and close with special tool 32 1 260 .

Due to the material thickness, an increased closing force is required!

NOTE: The diameters of the stepless ear clips are marked on the components!

Fig 6: Identifying Gaiter And Sealing Surfaces

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Gaiter must be bled after fitting in order to adapt the excess pressure generated during fitting to the ambient pressure!

Slide gaiter up to visible groove (1).

Bleed gaiter; carefully slide a suitable tool between gaiter and output shaft for this purpose.

Fig 7: Identifying Gaiter Groove

Courtesy of BMW OF NORTH AMERICA, INC.

Close new infinitely variable jubilee clip (1) dia. 33.5 mm with special tool 32 1 260 .

Fig 8: Identifying Stepless Ear Clip

Courtesy of BMW OF NORTH AMERICA, INC.

Installing inner joint gaiter:

Slide new gaiter (1) together with infinitely variable jubilee clip dia. 34.6 mm and retaining clip dia. 85 mm on to output shaft.

Installation note:

Push gaiter of joint on transmission side up to stop of gaiter on wheel side.

Fig 9: Identifying Gaiter

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Align tripod star so that phase (arrow) points towards output shaft!

Drive tripod star with special tool 00 5 500 onto output shaft until groove for circlip is exposed.

Fig 10: Installing Tripod Star Using Special Tool (00 5 500) Onto Output Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Install new copper-colored circlip (1).

Fig 11: Identifying Copper-Colored Snap Ring

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Packing of grease in the transmission-side joint must not exceed 100 g.
Only use grease from the repair kit or as specified in the BMW Electronic Parts Catalogue!

Pack lubricating grease into housing (1).

Fig 12: Identifying Housing

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: During assembly, the sealing faces on the gaiter and joint must be clean, dry and free of grease!

Attach packed housing (1) to tripod star and into gaiter (2).

NOTE: Make sure gaiter is correctly seated in groove in housing.

Fig 13: Identifying Packed Housing And Gaiter

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: The center point of clip must be level with the center line of the housing!
Max. deviation (A) ± 10 mm

Close new infinitely variable retaining clip dia. 85 mm with special tool 31 5 200 .

Fig 14: Identifying Max. Deviation Of Clamping Pipe

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: The stepless clamp must snap into place completely with both hooks! Both hooks must no longer be visible after engagement.
The closing travel is 13 mm.

Fig 15: Identifying Stepless Clamping Band

Courtesy of BMW OF NORTH AMERICA, INC.

Adjust gaiter (1) with housing to an installation length of 91.5 mm.

IMPORTANT: Gaiter must be bled after fitting in order to adapt the excess pressure generated during fitting to the ambient pressure!

Vent gaiter (1); carefully slide a suitable tool between gaiter and output shaft for this purpose.

Close new infinitely variable jubilee clip (2) dia.34.6 mm with special tool 32 1 260

Fig 16: Identifying Gaiter And Stepless Ear Clip

Courtesy of BMW OF NORTH AMERICA, INC.

Replace transmission circlip.

Fig 17: Identifying Circlip

Courtesy of BMW OF NORTH AMERICA, INC.