31 60 535 Replacing both gaiters on left and right of output shaft

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2019 MINI Cooper, 2018 MINI Cooper, 2017 MINI Cooper, 2016 MINI Cooper, and 2015 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

NOTE: Output shaft removed.

Attention !

Repair may only be carried out via the inner joint! Do not press off or disassemble wheel-side joint.

The transmission-side joint may be bent by max. 18° and the wheel-side joint by max. 45°!

Remove all traces of old grease from inner joint, wipe off old grease from outer joint!

Only use dry, clean cloth free of grease and lint for cleaning!

Visible soiling of joints (e.g. by water or dirt) will cause premature failure!

Fig 1: Output Shaft Dynamic Damper

Courtesy of BMW OF NORTH AMERICA, INC.

The wheel-side gaiter may not be replaced with output shafts that have a dynamic damper (1)!

Output shafts with dynamic damper (1) and faulty wheel-side gaiter require a complete replacement of the LEFT OUTPUT SHAFT or RIGHT OUTPUT SHAFT .

Fig 2: Detaching Band Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

Attention !

Always use plastic or aluminum vice jaw protectors when working with a vice!

Tensioning straps are not to be reused!

Clean the output shaft (2) and place it into the vice.

(1) = Wheel-side joint

(3) = Joint on transmission end

Detach the band clamps (1) and (2).

Slide the gaiter (3) back.

Fig 3: Detaching Joint Housing

Courtesy of BMW OF NORTH AMERICA, INC.

Detach joint housing (4).

Fig 4: Tripod Circlip And Output Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Detach the circlip (1) for the tripod (2) from the output shaft (3).

Fig 5: Pulling Tripod Off Output Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Use a three-claw extractor tool (3) to pull the tripod (1) off the output shaft and clean it carefully.

If necessary, use a suitable bolt (2) to close the bore hole.

Attention !

Remove all traces of old grease. Old gaiter must not be reused!

Fig 6: Detaching Gaiter Of Joint On Transmission Side

Courtesy of BMW OF NORTH AMERICA, INC.

Detach gaiter (1) of joint on transmission side and carefully clean output shaft.

Fig 7: Detaching Tensioning Straps

Courtesy of BMW OF NORTH AMERICA, INC.

Removing outer joint gaiter:

Attention !

The wheel-side constant velocity joint is pressed on and secured with a snap ring. Do not press off or disassemble!

Failure to comply with this instruction will result in damage to the constant velocity joint.

Detach the tensioning straps (1) and (2).

Detach gaiter (3) of joint on wheel side.

Fig 8: Joint Wipe Accessible Areas And Output Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Wipe accessible areas of joint (1) and the output shaft (2) with a clean and lint-free cloth.

Installing outer joint gaiter:

During assembly, the sealing surfaces on the gaiter and joint must be clean, dry and free of grease!

It is imperative to follow the grease and quantities listed in the table to top off the grease!

Gaiter part number	8 618 537	8 618 547	8 618 539	8 618 541	8 618 545	8 625 846
Gaiter part number	8 618 538	8 618 548	8 618 540	8 618 542	8 618 546	8 625 847
Joint on the transmission end
Grease quantity	125 g	125 g	140 g	140 g	170 g	170 g
Grease	CX-CVM1	CX-CVM1	CX-CVM1	CX-TP1	CX-TP1	CX-TP1
Wheel-side joint
Grease quantity	90 g	75 g	80 g	80 g	105 g	105 g
Grease	CX-CVL1	CX-CVL1	CX-CVL1	CX-CVL1	CX-CVL1	CX-CVL1

NOTE:

CX-CVM1 = Part number: 2 286 016
CX-TP1 = Part number: 2 286 018
CX-CVL1 = Part number: 2 286 017

Fig 9: Joint Wipe Accessible Areas And Output Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Push the new gaiter onto the output shaft.

Lubricate the joint with lubricant (see table).

NOTE: The sealing surfaces on the inside of the gaiter and the groove on the constant velocity joint must be dry, clean and free of grease.

Fig 10: Positioning Gaiter On Joint

Courtesy of BMW OF NORTH AMERICA, INC.

Position the gaiter (3) on the joint.

Attention !

Gaiter must be bled after fitting in order to adapt the excess pressure generated during fitting to the ambient pressure!

Bleed gaiter; carefully slide a suitable tool between gaiter and output shaft for this purpose.

Position the band clamp (1) and (2) in the gaiter groove and close it with special tool 32 1 260 .

Fig 11: Sliding Gaiter Onto Output Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Installing inner joint gaiter:

Slide the band clamp with the smaller diameter onto the output shaft (2).

Slide the new gaiter (1) onto the output shaft (2).

Fig 12: Tripod On Output Shaft Flat Side

Courtesy of BMW OF NORTH AMERICA, INC.

Attention !

Mount the tripod (2) on the output shaft so that the flat side (1) points toward the circlip.

Fig 13: Tripod Circlip And Output Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Drive tripod (2) with a suitable tool onto the output shaft (3) until the groove for the circlip is exposed.

Install the circlip (1).

Fig 14: Output Shaft And Circlip

Courtesy of BMW OF NORTH AMERICA, INC.

Lubricate the joint housing (4) with lubricant (see table).

Attention !

During assembly, the sealing surfaces on the gaiter and joint must be clean, dry and free of grease!

Mount the joint housing (4) on the tripod.

Mount the gaiter (3) on the joint housing (4).

Attention !

Gaiter must be bled after fitting in order to adapt the excess pressure generated during fitting to the ambient pressure!

Vent gaiter (3); carefully slide a suitable tool between gaiter and output shaft for this purpose.

Close the band clamps with the special tool 32 1 260 .

If necessary, close the low-profile band clamp with special tool 31 5 200 .

Fig 15: Locating Transmission Circlip

Courtesy of BMW OF NORTH AMERICA, INC.

Replace transmission circlip.