Replace clutch of rear axle differential (AWD)

Special tools required:

0 496 080 (33 5 206
0 496 080
2 460 340
F405 AC
A4CF405

WARNING: Poisoning hazard if oil is ingested/absorbed through the skin!
Danger of injury if oil comes into contact with eyes and skin!

Attention!

Risk of damage!

Failure to comply with the oil specifications will result in severe damage to the hang-on clutch!

Only use the approved oil (see applicable BMW Electronic Parts Catalog) for the hang-on clutch.
The oil to be filled must have min. room temperature (higher than 18°)
Maintain the exact OIL CAPACITY

Attention!

Risk of damage!

Failure to comply with the oil filling/emptying will result in severe damage to the hang-on clutch!

To ensure correct oil filling of the hang-on clutch, the oil circuit of the hang-on clutch must be completely emptied before filling (remove the hang-on clutch and swivel the transmission down).
To ensure correct oil filling of the hang-on clutch, the transmission must always be swiveled down, even when the oil is being filled.
The oil filler plug on the reservoir cap is not a fill level control plug!

Attention!

Read and comply with NOTES on protection against electrostatic discharge (ESD protection)!

NOTE: Replace the hang-on clutch only in conjunction with the control unit for longitudinal torque distribution!

Preliminary work needed:

Remove complete EXHAUST SYSTEM.
Remove the left-hand TORSION STRUT.
Remove the heat shield.
Remove and tie back the PROP SHAFT on the rear axle differential.

Removal:

Loosen screws (1).

Remove cover (2).

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Disconnect plug (2).

Loosen the connector (1) and loosen the cable (3) from the control unit bracket.

Loosen screws (4).

Remove control unit (5) together with holder.

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Loosen screws (1).

Remove the longitudinal torque distribution control unit (2) from the holder (3).

Loosen the cable from the holder (3).

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Attention!

Injury hazard!

Check the luggage straps for visible damage before each use.
Do not install the tensioning belt in a twisted position.

Risk of damage!

Failure to comply may cause damage to the output shaft/dust plate.

The tensioning belt must not rest against the dust plate of the output shaft.
The tensioning belt must not rest against the bellows of the output shaft.

Before releasing the rear axle differential, secure or hook the rear axle differential with tensioning belt 0 496 080 (33 5 206).

Guide the tensioning belt 0 496 080 between the body, cross-member (1) and rear axle support (2).

Guide tensioning belt 0 496 080 around the output shaft, connect and tension both ends.

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Only slacken screws (1).

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Support rear axle differential (1) with universal jack (2).

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Release screw (1) of the rear axle differential.

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Release screws (1) of the transmission cross member on the rear axle differential.

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Attention!

Risk of damage!

Failure to comply may cause damage to the output shaft/dust plate.

The tensioning belt must not rest against the dust plate of the output shaft.
The tensioning belt must not rest against the bellows of the output shaft.

Lower the transmission with the universal jack.

Rear axle differential by maximum 22-27 cm (distance from the body to the center of the output shaft).

Adjust the length of the tensioning belt accordingly.

Remove the universal jack and swivel/tilt the rear axle differential downwards.

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Release oil filler plug (1) on the oil expansion tank.

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Recycling:

Catch and dispose of leakage transmission oil.

Observe country-specific waste disposal regulations.

Place oil drip tray under rear axle differential.

Release screws (1) of hang-on clutch (2).

Pull out hang-on clutch (2) downwards from the clutch housing.

Let the oil drain completely from the transmission housing.

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When reinstalling or before the disposal:

Turn the hang-on clutch 360° so that all the oil (especially from the pump suction chamber) runs out.

Installation:

Coat sealing ring (1) with oil.

Installation note:

Replace sealing ring (1).

Parts: Sealing ring

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Insert the hang-on clutch in the clutch housing.

Pull in the hang-on clutch by evenly tightening screws (1) crosswise.

Tighten down screws (1).

Tightening torque 33 10 1AZ .

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Attention!

Risk of damage!

Failure to comply with the oil specifications will result in severe damage to the hang-on clutch!

Only use the approved oil (see applicable BMW Electronic Parts Catalog) for the hang-on clutch.
The oil to be filled must have min. room temperature (higher than 18°)
Maintain the exact OIL CAPACITY

Installation note:

Use special tool 2 460 340 to top up the oil in the hang-on clutch.

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Screw special tool F405 AC for the oil spray nozzle into the oil filler cap.

Tightening torque: Maximum 2 Nm

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Connect special tool 2 460 340 to the transmission.

Top up the oil slowly.

Attention!

Only use the approved oil for the hang-on clutch.

Maintain the exact OIL CAPACITY .

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Remove special tool 2 460 340.

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Remove special tool A4CF405 on the hydraulic fluid reservoir.

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Installation note:

Replace the sealing ring of the oil filler plug.

Parts: Sealing ring

Screw in and tighten oil filler plug (1).

Tightening torque 33 11 2AZ .

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Swivel the rear axle differential with the universal jack upwards.

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Support rear axle differential (1) with universal jack (2).

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Screw in screw (1) of the rear axle differential by hand.

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Position the rear axle differential on the transmission cross member.

Tighten screws (1) on the transmission cross member.

Tightening torque 33 17 2AZ .

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Tighten screw (1) of the rear axle differential.

Tightening torque 33 17 1AZ .

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Remove special tool 0 496 080.

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Position the longitudinal torque distribution control unit (2) on the holder (3).

Ensure correct cable routing.

Tighten down screws (1).

Tightening torque 33 10 2AZ .

Secure the cable to the holder (3).

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Position control unit (5) with holder on rear axle differential.

Tighten down screws (4).

Tightening torque 33 10 3AZ .

Attach connector (2).

Secure the cable (3) to the control unit bracket and connect the connector (1).

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Position cover (2).

Tighten down screws (1).

Tightening torque 33 31 8AZ .

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Required follow-up work:

Fit the PROP SHAFT on the rear axle differential.
Install heat shield.
Install the left-hand TORSION STRUT. .
Completely install the EXHAUST SYSTEM .
PROGRAM/ENCODE control unit.
Carry out the hang-on clutch oil bleeding procedure.
Service function -> Drivetrain > Longitudinal torque distribution -> Bleeding

Waiting period of 60 seconds

Carry out the service function "bleeding procedure" again