Rear Axle Final Drive 3...

331-1

General
This repair group cover removal and
repair information for the rear drive axle
shafts, CV joints and CV joint boots.
Also covered is rear differential (final
drive) removal procedures and seal
replacement information.

Internal repairs of the differential

assembly are not covered in this
manual.

Special tools

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BMW recommends some special tools
for the removal of the drive axles as
well as the installation of rear
differential input and output drive
flange seals. Some common pullers
and drifts can often be substituted for
these tools.

Radial seal puller BMW 00 5 010

Flange counterhold tool BMW 23 0 020

Drive axle puller BMW 33 2 110

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Output flange seal drift BMW 33 3 400

Input flange seal drift BMW 33 3 430

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331-2

Drive Axles

The drive axles use constant-velocity

(CV) joints on both ends. Two different
styles of CV joints have been supplied
with E46 vehicles. Refer to the
accompanying illustration:

Ball cage CV joint. Traditional

design CV joint with thick metal
housing (approx. 40 mm/1.6 in.
thick). Balls slide in non-parallel
grooves.

Slip sleeve CV joint. Thin bolt-on

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flange (approx. 15 mm/0.6 in.
thick). CV joint has splined shaft
that slides into end of axle.

For replacement parts, only CV joints

boots or complete axles are offered by
BMW. To replace a CV joint boot, the
drive axle must be removed from the
car. The rear axle shafts are different in
length. The shorter of the two shafts is
located on the left side, the longer
shaft on the right.

Rear drive axle, removing and

installing

With an assistant applying brakes,

break free staked collar nut (arrow) at
center of rear wheel hub. Do not
remove completely.

Note:

The drive flange collar nut is tightened

to a torque of over 250 Nm (184 ft-lb).
Make sure the car is firmly on the
ground.

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- Raise rear of car. Remove rear

wheel.

WARNING!

Make sure that the car is firmly

supported on jack stands designed
for the purpose. Place the jack
stands beneath a structural chassis
point. Do not place jack stands
under suspension parts.

- Detach rear stabilizer bar anchor

bolts from rear subframe and tilt
stabilizer down.

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- Working on left axle: Detach rear
of exhaust system and tilt down.
Support rear muffler securely.

Remove drive axle to differential

mounting bolts (arrows). Detach drive
axle from drive flange. Suspend drive
axle from chassis using stiff wire.

Press drive axle from wheel bearing

housing using an appropriate puller.

- Installation is reverse of removal.

Apply a light coating of oil to

contact face of collar nut and
install it loosely.

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Install road wheel and lower car to

ground.

With an assistant applying brakes,

tighten drive axle collar nut to its
final torque.

Stake and caulk collar nut.

Tightening torques
Drive axle collar nut to drive flange
M24 250 Nm (184
ft-lb)

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M27 300 Nm (221
ft-lb)
Drive axle to differential flange
M10x20 mm Torx
bolt 83 Nm (61 ft-lb)
M10x46 mm bolt
(black) 100 Nm (74 ft-lb)
M10x46 mm bolt
(silver) (always
replace) 80 Nm (59 ft-lb)
Road wheel to hub 100 ± 10 Nm
(74 ± 7 ft-lb)

Rear drive axle assembly

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CV joint boots

Note:

When replacing a CV joint boot, use

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a complete CV joint boot repair kit.
The kit will include a new boot,
clamping bands, special lubricant,
and a new inner CV joint circlip. The
kit is available from an authorized
BMW dealer parts department.

The outer CV joint cannot be

removed from the axle shaft. In
order to replace the outer CV boot, it
is necessary to remove the inner
joint and boot first.

If the CV joints are worn or

defective, a complete rebuilt axle
shaft is available from an authorized
BMW dealer parts department.

Working with axle shaft at bench, cut off

old boot clamps and remove boots.
Clean old grease off joints and shafts.
Use new grease from CV joint boot kit.

Ball cage CV joint boot

Lift off dust cover from inner CV joint and

remove circlip (arrow) retaining joint

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inner hub to axle shaft.

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Support inner hub at arrowswhen
pressing axle shaft out of joint.

- Clean all old lubricant off shaft

splines and inner joint's splines.

CAUTION!

If the CV joint must be disassembled

for cleaning and inspection, be sure to
matchmark inner and outer race and
intermediate ball cage. This allows
reassembly of parts in their original
positions.

Note:

To inspect a CV joint, clean away the

grease and look for galling, pitting and
other signs of wear or physical damage.
Polished surfaces or visible ball tracks
alone are not necessarily cause for
replacement. Discoloration due to
overheating indicates lack of lubrication.

- Apply Loctite® 270 or an equivalent

heavy-duty locking compound to
drive axle splines. Position new CV
joint on shaft so that raised or taller

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side of hub is facing shaft.

WARNING!

Do not let the locking compound

contact the balls in the joint. Apply
only a thin coat to cover the splines.

- While supporting axle shaft, press

inner hub of CV joint onto shaft.
Install new circlip.

Note:

Do not let the ball hub pivot more

than 20 in the outer ring of the joint.
The balls will fall out if the hub is

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pivoted too far.

Before installing each small boot

clamp be sure to "burp" the boot by
flexing the CV joint as far over as it
will go. A small screwdriver inserted
between the boot and the axle shaft
will help the process.

BMW recommends Bostik®1513 or

Epple®4851 adhesive, and
Epple®39 or Curil®T sealer.

CV joint lubricant capacity

Wheel hub end 80 gram (2.8 oz.)
Differential end 85 gram (3.0 oz.)

- Use sealing gel to seal dust cover

to CV joint prior to reinstallation.

Slip sleeve CV joint boot

- Pull CV joint partially out of axle

shaft. Matchmark relative position of

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joint to shaft.

CAUTION!

If the joint and shaft are not

reassembled in their original position
the assembly may be out of balance
and vibrate during operation.

When reinstalling joint, push joint into

shaft as far as it will go, then pull it out
to measurement A(16 mm / 0.6 in.).

Note:

This step insures uniform lubrication of

the CV joint.

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- Keep joint in position while
installing inner (small) boot clamp.

- Make sure sealing lip of joint and

boot are free of grease. The boot
could otherwise slide off when boot
clamp is tightened.

Slip sleeve joint boot lengths

Inner boot 65 mm (2.6 in.)
Outer boot 55 mm (2.2 in.)

Note:

On the differential end CV joint,

position large boot clamp so that
crimp in clamp faces rivet on CV
joint flange.

Install large clamps of inner and

outer CV joints so that the crimps
are offset by 180°.

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331-3

Rear Differential
All rear differential work requires some
method of raising the car and
supporting it securely while the work is
performed. Jack stands and a floor jack
can easily be used, but use extreme
caution when working beneath the car.
See 010 General.

Note:

Removal of rear subframe (differential

carrier) is covered in 330 Rear
Suspension.

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Rear differential oil, checking
and filling

Note:

BMW supplies the E46 rear differential

with lifetime lubricant.

To check rear differential oil level:

Remove oil filler plug.

Insert finger into fill hole. If finger

is wetted from oil, level is correct.

Note:

Use a 14 mm Allen socket to remove

the fill or drain plug. Alternatively, cut
approximately 30 mm (1.2 in) from an
Allen key and use a box end wrench on
the key stub.

- If necessary, fill differential with

appropriate type and quantity of
lubricant.

Note:

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The differential fluid level is correct

when the fluid begins to spill from the
fill plug.

- Install and tighten fill plug.

Differential oil
Differential oil capacity
Rear wheel drive 0.9 liter (0.95 US
qt.)
All wheel drive 1.0 liter (1.06 US
qt.)
Oil specification BMW SAF-XO
synthetic oil

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Tightening torques
Differential drain or
fill plug 70 Nm (52 ft-lb)

Rear differential, removing and

installing

- Raise rear end of car and support

it securely on jack stands.

WARNING!

Make sure that the car is firmly

supported on jack stands designed
for the purpose. Place the jack
stands beneath a structural chassis
point. Do not place jack stands
under suspension parts.

- Remove rear drive axles.

- If necessary, drain differential oil.

Remove rear suspension reinforcement

brace:

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Remove heat shield between

reinforcement brace and exhaust
pipe.

Remove bolts (A) mounting brace

to undercarriage.

Remove nuts (B) mounting brace

and front of rear subframe to
undercarriage.

Lower and remove reinforcement.

Note:

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If necessary, tilt rear half of exhaust
system down. Support exhaust system
securely.

- Detach driveshaft from differential

input shaft flange and suspend.
See 260 Driveshaft.

CAUTION!

Suspend the detached drive axle

from the car body with a stiff wire
hook to prevent damage to the outer
CV joint.

- Remove rear stabilizer bar.

Support differential with transmission

jack. Remove rear (A) and front (B)
mounting bolts at subframe.

- Slowly lower differential unit and

remove toward rear.

- Installation is reverse of removal.

In order to prevent excess
vibration and noise, follow
sequence for tightening

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differential mounting bolts:

Install bolts finger tight.

Tighten front bolts (B).

Tighten rear bolt (A).

Tightening torques
Differential drain or
fill plug 70 Nm (52 ft-lb)
Differential to rear subframe
Front mount (M12

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bolts) 95 Nm (70 ft-lb)
Rear mount (M14 174 Nm (128
bolt) ft-lb)
Drive axle to differential flange
M10x20 mm Torx
bolt 83 Nm (61 ft-lb)
M10x46 mm bolt 100 Nm (74
(black) ft-lb)
M10x46 mm bolt
(silver) (always
replace) 80 Nm (59 ft-lb)
Driveshaft to differential flange
M10 compression
nut 64 Nm (47 ft-lb)
M10 Torx bolt 85 Nm (63 ft-lb)
Rear suspension reinforcement to
undercarriage
M12 self-locking
nut 77 Nm (57 ft-lb)
M8 bolt 8.8 grade 21 Nm (15 ft-lb)
M8 bolt 10.9 grade 30 Nm (22 ft-lb)

- Be sure to refill differential.

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Differential oil
Differential oil capacity
Rear wheel drive 0.9 liter (0.95 US
qt)
All wheel drive 1.0 liter (1.06 US
qt.)
Oil specification BMW SAF-XO
synthetic oil

Differential mounting bushings

- If rear differential mounting

bushing are worn, damaged or oil

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soaked:

Remove differential from rear

subframe.

Working at subframe, use bushing

press tools to remove old
bushings and install new ones.

Carefully note installation marks

(arrows) on new bushings.

Note:

BMW uses bushings from different

manufacturers in the course of
production. Always check with an
authorized BMW dealer for the latest
information on suspension bushings.

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331-4

Rear Differential Oil

Seals
Low oil level caused by faulty oil seals
may be the cause of noisy differential
operation. The drive flange (side) and
input shaft (front) oil seals can be
replaced while the differential is
installed.

Note:

Do not mistake leaking CV joints for

flange seal leaks. It may be helpful to
degrease the differential to pinpoint the
source of the leak prior to replacing

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seals.

Output drive flange oil seal,

replacing

- Raise car and support safely.

WARNING!

Make sure that the car is firmly

supported on jack stands designed
for the purpose. Place the jack
stands beneath a structural chassis
point. Do not place jack stands
under suspension parts.

- If working on left side: Detach rear

of exhaust system and tilt down.
Support rear muffler securely.

- Detach stabilizer bar from rear

subframe.

- Detach drive axle from differential

as described earlier.

CAUTION!

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Rear Axle Final Drive 3...

Suspend the detached drive axle

from the car body with a stiff wire
hook to prevent damage to the outer
CV joint.

Pry output flange from differential. For

leverage, use a wooden dowel as
shown.

Note:

Be prepared to catch dripping oil in

a pan.

Inspect flange at the point where

the oil seal rides on the shaft.

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Replace the flange if there is a
groove worn in the shaft.

- Pry old oil seal from its recess

using BMW special tool 00 5 010
or equivalent seal puller.

CAUTION!

Be careful not to mar the differential

housing when removing the seal.

- Dip new seal in differential

lubricant and drive into place until
fully seated.

Replace locking circlip (arrow) on

output flange.

- Install flange by pressing it in by

hand until snap ring engages. It
may be necessary to turn flange
slightly while pushing.

- Attach drive axle and tighten bolts.

- Top off differential with oil.

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Rear Axle Final Drive 3...

Tightening torque
Drive axle to differential flange
M10x20 mm Torx
bolt 83 Nm (61 ft-lb)
M10x46 mm bolt
(black) 100 Nm (74 ft-lb)
M10x46 mm bolt
(silver) (always
replace) 80 Nm (59 ft-lb)

Input drive flange oil seal,

replacing

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- Raise car and support safely.

Remove rear suspension reinforcement

brace:

Remove heat shield between

reinforcement brace and exhaust
pipe.

Remove bolts (A) mounting brace

to undercarriage.

Remove nuts (B) mounting brace

and front of rear subframe to
undercarriage.

Lower and remove reinforcement.

Note:

If necessary, tilt rear half of exhaust

system down. Support exhaust system
securely.

- Remove driveshaft from differential

input shaft flange. See 260
Driveshaft. Tie end of driveshaft to

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Rear Axle Final Drive 3...

side.

Make matching marks on differential

input shaft, collar nut and driveshaft
flange.

- Pry lock plate from nut.

Counterhold input flange with
BMW special tool 23 0 020 or
equivalent and remove collar nut.

- If necessary, use puller to remove

input flange.

Note:

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Be prepared to catch dripping oil in a
pan.

- Pry old oil seal from its recess

using BMW special tool 00 5 010
or equivalent seal puller.

CAUTION!

Be careful not to mar the differential

housing when removing the seal.

- Dip new seal in differential

lubricant and drive it into position.

- Lightly lubricate input shaft and

press input flange back on. Install
collar nut and slowly tighten until
matching marks line up.

- Install a new lock plate and refill

differential with lubricant.

CAUTION!

If the flange collar nut is tightened

past the marks, interior components
of the differential will be damaged.

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Differential oil
Differential oil capacity
Rear wheel drive 0.9 liter (0.95 US
qt)
All wheel drive 1.0 liter (1.06 US
qt.)
Oil specification BMW SAF-XO
synthetic oil

- Remainder of assembly is reverse

of disassembly.

Tightening torques

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Driveshaft to differential flange
M10 compression
nut 64 Nm (47 ft-lb
M10 Torx bolt 85 Nm (63 ft-lb)
Differential drain or
fill plug 70 Nm (52 ft-lb)

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