Removing and installing/replacing right output shaft (Cooper)

Attention! 

Manual transmission only: 

• After each removal of the output shaft, the RADIAL SHAFT SEAL in the transmission must be replaced.

Preliminary work needed: 

• Remove front WHEEL .
• Manual transmission only:  Drain and catch TRANSMISSION OIL .
• Only vehicles with TU0 engine:  Disconnect BATTERY GROUND LEAD .

Observe the next two figures for the identification of the engine.

TU0 Engine:  Positive battery cable (2) and terminal 50 (1) on the starter motor are not  protected against contact.

Courtesy of BMW OF NORTH AMERICA, INC.

TU1 Engine:  Positive battery cable (2) and terminal 50 (1) on the starter motor are protected against contact.

Courtesy of BMW OF NORTH AMERICA, INC.

Removal: 

If necessary, lever off protective cap (1).

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Secure output shaft against falling out.

Turn steering wheel to right.

Pull out output shaft (1).

Courtesy of BMW OF NORTH AMERICA, INC.

If necessary, release screws (1) and remove holder (heat shield) (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Unscrew the screws (1).

Pull output shaft (2) out of transmission and remove to one side.

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

Attention! 

Manual transmission only: 

• Replace RADIAL SHAFT SEAL .

Attention! 

With automatic transmission only: 

• Lever out O-ring (1).

Part:  Replace O-ring.

• Insert new O-ring (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Insert assembly protection ring (1) into the radial shaft seal.

• The installation protection ring (1) is provided with a new radial shaft seal for the 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.

Courtesy of BMW OF NORTH AMERICA, INC.

Insert output shaft (1) into transmission.

Before the sealing surface is pushed into the radial shaft seal, remove assembly protection ring (2) by pulling the handle.

Slide output shaft into transmission up to stop.

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten down screws (1).

Tightening torque 31 60 1AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Turn steering wheel to right.

Insert output shaft (1) from the front into the pivot bearing.

Courtesy of BMW OF NORTH AMERICA, INC.

• Pay attention to installation position of compression spring (2).
• Keep collar screw and spur toothing of wheel bearing/output shaft clean and free of grease

Attention! 

Following installation note for spur gearing must be observed without fail!

Courtesy of BMW OF NORTH AMERICA, INC.

Part:  Replace collar screw and compression spring.

Tighten collar screw (1) and compression spring hand force.

Courtesy of BMW OF NORTH AMERICA, INC.

• Spur gearing of wheel bearing (1) and output shaft (2) must be installed form-fit (tooth in tooth position)!

Check whether spur gearing is locked tooth in tooth by reciprocally rotating wheel hub/output shaft.

Once positive locking has been ensured, tighten screw connection to the specified torque.

Tightening torque 31 60 2AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

If necessary, attach protective cap (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work: 

• Manual transmission only:  Add transmission fluid.
  • The vehicle must be level when the transmission oil is filled.
• Check transmission for leaks.
• Install front WHEEL .
• Connect BATTERY GROUND LEAD .