Removing and installing/replacing right output shaft (AWD)

Special tools required: 

• 2 406 773
• 33 5 120
• 0 496 862
• 33 5 122
• 2 406 774

Courtesy of BMW OF NORTH AMERICA, INC.

Attention! 

• RADIAL SHAFT SEAL  for output shaft in right rear axle differential must be replaced each time after removal.

Preliminary work needed: 

• Remove right rear WHEEL .

Removal: 

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.

• Remove the BRAKE PADS .
• Remove rear BRAKE DISK .
• Remove the rear left PULSE GENERATOR on the trailing arm.

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) and remove the wheel bearing.

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

Press out right output shaft 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.

Push output shaft (1) axially through trailing arm (2) until the drive flange is guided out of the rear axle differential.

Remove output shaft (1) downwards.

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

• Replace RADIAL SHAFT SEAL  in right rear axle differential.

Attention! 

Make sure the installation protection ring has been reinstalled before inserting the output shaft.

Open installation protective ring (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Replace snapring of output shaft.

Parts  : snapring

Courtesy of BMW OF NORTH AMERICA, INC.

Guide in output shaft (1) axially through trailing arm (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Align output shaft (1) and slide it into the rear axle differential.

Courtesy of BMW OF NORTH AMERICA, INC.

Guide output shaft (1) into the transmission.

After having inserted the output shaft pull on the installation protection ring lug (3) until one of the two predetermined breaking points gives in.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Drive output shaft with special tool 2 406 774 and a rubber mallet into rear axle final drive.

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note: 

• Keep contact surface (2) of wheel bearing (1) and swivel bearing clean and free from grease.

Courtesy of BMW OF NORTH AMERICA, INC.

Attention! 

Risk of damage: 

Make sure that neither the tensioning strap nor the corrosion protection coating is damaged when removing and installing the output shaft.

Failure to comply will result in corrosion and loss of lubricant!

Courtesy of BMW OF NORTH AMERICA, INC.

Install wheel bearing.

Replace screws (1).

Parts  : Screws

Tighten down screws (1).

Tightening torque 33 41 1AZ .

• Install the rear BRAKE DISC .
• Install rear BRAKE PADS .
• Install the rear left PULSE GENERATOR on the trailing arm.

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

Attention! 

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

Courtesy of BMW OF NORTH AMERICA, INC.

Position output shaft on wheel bearing.

Replace collar screw and compression spring.

Parts  : Collar screw and compression spring

Tighten collar screw (1) and compression spring hand-tight.

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 established, fully depress the brake pedal and tighten the screw.

Tightening torque 33 41 2AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Connect protective cap (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work: 

• Check OIL LEVEL in the rear axle differential.
• Mount right REAR WHEEL .