Replacing the complete rear axle differential (AWD)

Special tools required:

2 358 630
23 4 150
2 406 773
33 5 120
0 496 862
33 5 122
33 5 200
2 406 774

Courtesy of BMW OF NORTH AMERICA, INC.

Attention!

The rear axle final drive must not be tilted by more than 45° during the installation procedure.
The snaprings on the two output shafts must be replaced!

NOTE:

The new rear axle differential is delivered completely filled with all oils.
The oil level therefore does not have to be checked.

In rare cases, the new rear axle differential may be contaminated by the oil that leaked out during transportation.

In this case, the OIL LEVEL in the rear axle differential must be checked and supplemented. The hang-on clutch is emptied fully and refilled. If oil has leaked through the exhaust fan on the clutch on the rear axle differential, the exhaust fan must be replaced.

Preliminary work needed:

Remove right rear WHEEL .
Remove complete EXHAUST SYSTEM.
Remove heat shields.
Remove and tie back PROP SHAFT on rear axle differential.
Remove the right TANK COVER .
Remove right COIL SPRING .

Removal:

Loosen screws (1).

Remove cover (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect connector (1) from control unit.

Loosen cable (2) from control unit bracket.

Courtesy of BMW OF NORTH AMERICA, INC.

Secure special tool 2 358 630 to the drive flange with lug bolts.

Press wheel hub upward with special tool 2 358 630 and workshop jack.

Courtesy of BMW OF NORTH AMERICA, INC.

Support rear axle differential (1) with workshop jack and special tool 23 4 150.

Secure rear axle differential against falling out with luggage strap (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Insert support tool 2 406 773 in the bore on the rear axle differential.

Press left and right output shafts out of rear axle differential with jerky movements using special tool 33 5 120 and shaped part 0 496 862.

Position the thrust piece of screw 33 5 122 on support tool 2 406 773.

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1) of rear axle differential.

Courtesy of BMW OF NORTH AMERICA, INC.

Undo screws (1) on left and right of cross member (2) (right side identical).

Courtesy of BMW OF NORTH AMERICA, INC.

Lower rear axle differential (1).

Feed output shafts out of transmission by shifting rear axle differential sideways.

Remove rear axle final drive.

Courtesy of BMW OF NORTH AMERICA, INC.

Do not allow output shafts (1) to hang in the joints.

Tie up the output shafts (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Remove the rear axle differential to be replaced from the special tool 33 5 200.

Place new rear axle differential on special tool 33 5 200 and secure with luggage strap.

Replace snapring of output shafts.

Parts : snaprings

Courtesy of BMW OF NORTH AMERICA, INC.

Attention!

Before guiding in the output shafts, ensure that the installation protection rings have been installed.

Fold open installation protection rings (1) on left and right.

Courtesy of BMW OF NORTH AMERICA, INC.

Guide the left and right output shaft (1) into the transmission by shifting the rear axle differential (2) sideways.

After feeding in the output shafts, pull the lug (3) of the installation protection ring until one of the two predetermined breaking points gives way.

Pull out the installation protection rings (3) and dispose of them.

Courtesy of BMW OF NORTH AMERICA, INC.

Raise rear axle differential (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten screw (1) of rear axle differential hand force.

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten screws (1) on left and right of cross member (2) (right side identical).

Tightening torque 33 31 3AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten screw (1).

Tightening torque 33 17 1AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Special tool 2 406 774 must be inserted into the circumferential slot (1) of the output shaft!

Courtesy of BMW OF NORTH AMERICA, INC.

Strike the output shafts into the rear axle differential using special tool 2 406 774 and a rubber mallet.

Courtesy of BMW OF NORTH AMERICA, INC.

Lower workshop jack.

NOTE: Do not remove special tool 2 358 630 yet (required to install the coil spring).

Courtesy of BMW OF NORTH AMERICA, INC.

Secure cable (2) on control unit bracket.

Connect connector (1) to control unit.

Courtesy of BMW OF NORTH AMERICA, INC.

Position cover (2).

Tighten down screws (1).

Tightening torque 33 31 8AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work:

Install the right COIL SPRING .
Install right TANK COVER .
Install PROP SHAFT on rear axle differential.
Install heat shields.
Completely install the EXHAUST SYSTEM .
Mount right rear WHEEL .
If necessary, check the OIL LEVEL in the rear axle differential and, if necessary, correct it.
Carry out PROGRAMING/CODING the rear axle differential control unit.