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 may only be carried out via 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

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Remove circlip (1).

Fig 2: Identifying Snap Ring

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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)

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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

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Manual gearbox only:

Press vibration absorber (1), if fitted, off output shaft (2) with press.

Vibration absorber must not be reused.

Replace vibration absorber -> Follow procedure.

Fig 5: Pressing Vibration Damper Of Output Shaft Using Press

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

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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 pack with lubricating grease.

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

Fig 7: Identifying Gaiter And Sealing Surfaces

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Push packed gaiter together with infinitely variable jubilee clip Ø 92.0 mm on to joint on wheel side.

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

Align gaiter to shaft shoulder with dimension (A) = 4 mm.

Position a new infinitely variable jubilee clip Ø 92 mm in the gaiter groove and close with special tool 32 1 260 .

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

Fig 8: Identifying Gaiter Aligning Dimension

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

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

NOTE: Make sure gaiter is correctly seated in groove of output shaft.

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

Fig 9: Identifying Clamping Band

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Manual gearbox only:

Even if no vibration absorber was mounted on the shaft, the new vibration absorber must still be installed.

Push back vibration absorber to shaft shoulder (1) on inner joint (note following operation).

Fig 10: Identifying Shaft Shoulder

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Pressing on vibration absorber:

Coat vibration absorber and output shaft with Tip Top tire-fitting paste (BMW part no. 81 22 9 407 288).

Grip output shaft in vice (aluminium clamps) and push vibration absorber (1) by hand onto output shaft.

IMPORTANT: Aerate for at least 4 hours prior to returning to customer.

Fig 11: Identifying Vibration Damper

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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:

In vehicles with an automatic transmission, slide gaiter of transmission-side joint to the stop of the wheel-side gaiter, and in vehicles with a manual transmission, to the vibration absorber.

Fig 12: Identifying Gaiter

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

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Install new copper-colored circlip (1).

Fig 14: Identifying Copper-Colored Snap Ring

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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 15: Identifying Housing

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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 16: Identifying Packed Housing And Gaiter

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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 17: Identifying Max. Deviation Of Clamping Pipe

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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 18: Identifying Stepless Clamping Band

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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 19: Identifying Gaiter And Stepless Ear Clip

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Replace transmission circlip.

IMPORTANT: Service kit contains two circlips for different transmission versions. The ring for the automatic transmission is marked with label "A". Check for correctness before installing the circlip.

Fig 20: Identifying Circlip

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IMPORTANT: The circlips shown in the cross-section (mm) must not exceed the maximum outer diameters specified below after installation.

M - Manual transmission

A - Automatic transmission

Fig 21: Identifying Automatic Transmission And Manual Transmission Dimension

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