31 60 004 Removing and installing/replacing right output shaft

Release collar nut (1), press brake pedal to floor for this purpose.

Fig 1: Identifying Collar Nut

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Remove TRACK ROD END FROM SWIVEL BEARING on right.

Remove WISHBONE FROM RIGHT WHEEL CONTROL JOINT .

Use special tools (available via BMW/MINI):

• Hydraulic unit - 81 64 2 155 744
• Adapter kit 1 - 81 64 2 155 745
• Adapter kit 2 - 81 64 2 155 746
• Adapter - 81 64 2 318 661

The following work steps describe pressing out the output shaft: 

Fig 2: Pressing-Out The Output Shaft

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The following tools are required to press out the output shaft from the drive flange, see illustration for arrangement:

Vehicle components: 

Required components for all models and types: 

Secure output shaft against falling out.

Press out output shaft with hydraulic unit.

Press swivel bearing (1) outwards.

Pull out output shaft (2).

Fig 3: Removing Output Shaft From Wheel Bearing

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Unfasten screws (2).

Lever output shaft (1) out of transmission and remove.

Installation note: 

Manual gearbox only:

• Replacing radial shaft seal for output shaft. See REPLACING RIGHT RADIAL SHAFT SEAL or REPLACING RIGHT RADIAL SHAFT SEAL (ALL-WHEEL DRIVE) .

Fig 4: Removing Output Shaft

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Installation note: 

Replace circlip.

Fig 5: Locating Circlip

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Installation note: 

• Insert assembly guard (1) into radial shaft seal.
  • Assembly guard (1) is provided with new radial shaft seal for output shaft.

Make sure the tool fits over the lip of the radial shaft seal so there is no damage to sealing ring when the output shaft is inserted.

Fig 6: Identifying Assembly Guard

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Installation note: 

• With automatic transmission only:

  Replace O-ring (1).

Fig 7: Identifying O-Ring

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Installation note: 

Insert output shaft (1) into gearbox.

• Manual gearbox only:

  Before sealing surface is pushed into radial shaft seal, remove assembly guard (2) by pulling on handle.

Slide output shaft into gearbox up to stop.

Output shaft coupling must snap audibly into place. Check secure seating by levering.

Fig 8: Inserting Output Shaft Into Gearbox

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Installation note: 

Fit and tighten down screws (2).

Tightening torque 31 60 1AZ .

Fig 9: Removing Output Shaft

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The following work steps describe drawing in the output shaft: 

Fig 10: Fitting Output Shaft In Drive Flange

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The following tools are required to fit the output shaft in the drive flange, see illustration for arrangement:

Vehicle components: 

Required components for all models and types: 

Components specific to model and type (thread diameter, output shaft): 

The G4 special tool sleeve used has relatively thin walls due to its technical requirements. So that the load limits of the clamping sleeve are not exceeded when pulling in the output shaft, the adapter 81 64 2 318 661 must  be used together with a torque wrench.

Fig 11: Fitting Adapter With Torque Wrench To Hydraulic Unit

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Fit adapter with torque wrench to hydraulic unit (see illustration).

Set torque wrench to 20 Nm.

Draw in output shaft with hydraulic tool until the torque wrench is activated.

Tighten collar nut (1) by operating the brake.

Tightening torque 31 60 2AZ .

Installation note: 

Renew collar nut (1), apply a light coating of oil to collar nut contact surface and tighten.

No oil permitted on thread of shaft journal or collar nut.

Secure collar nut (1) by positive peening at flat areas of output shaft.

Fig 12: Locating Collar Nut

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After installation: 

• Manual gearbox only: Add transmission oil.
• Check gearbox for leaks