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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > Never heard of anyone experiencing such thing, broken rear diff?



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      09-23-2012, 08:49 PM   #1
Quebequer
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Never heard of anyone experiencing such thing, broken rear diff?

Hi all,
Since about 2 month, I've been experiencinng a weird issue, and it seems that it happens more frequently now.
Car is XI, 52k miles, still on extended warranty (6yrs/100k miles).
When I engage a gear at really low RPM, and I accelerate moderately, between about 1200rpm to 2000rpm, it's like if the car was hesitating, but let me explain. No hesitation from the engine whatsover, engine runs fine, hesitation seems to come from the drivetrain. I feel it in my back, and it comes from the back of my car, where the rear diff is. It happens sporadicaly, not all the time. It does it in all gears. Yesterday, when logging 3rd gear, I floored it at about 1100rpm. When I hit some higher boost (10+psi), at about 1700rpm, I felt and heard a big "bang" coming from the rear of the car. Looked at the log and it was perfect. It did that only one time on about 10, but the feel of it was scary.
Anyone has experienced such thing? Could it be a broken rear diff? Broken/worn gears inside diff?There is no noise no matter speed, and over 2000rpm it's fine even if I floor it. Car has been FBO for 23k miles and FBO w/ meth for 8k.
As said before, it is more and more frequent now, and it is pretty anoying.
I tried on map 0, stock map, and same thing but a little bit more subtile.
Opinions?
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Last edited by Quebequer; 09-23-2012 at 08:56 PM.
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      09-23-2012, 09:15 PM   #2
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Happened to my buddies turbo'd Miata...





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      09-24-2012, 02:07 AM   #3
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You'll just have to get under the car and take a look. It could've been something breaking in the driveline or rear suspension like a bolt or brace. If the teeth on the diff broke off you can just drain the diff fluid and look for metal particles mixed in the oil.
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      09-24-2012, 02:19 AM   #4
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Turn traction control fully off and try again.
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      09-24-2012, 06:42 AM   #5
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Quote:
Originally Posted by phil200tdi View Post
Turn traction control fully off and try again.
Lol this is not the problem.
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      09-24-2012, 09:14 AM   #6
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Quote:
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Lol this is not the problem.
this sounds like a transimmision issue just becuase of the fact that you have an open diffieretial making breaking anything in it highly unlikely you may want to look at you cv joints though i believe those go on manual cars with hard launches
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      09-24-2012, 09:57 AM   #7
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Just came back from the dealer, car is going in friday. They told me it was probably the rear diff alltought they were not sure.
The feeling of it is really weird. It seems to happen only when the transmission engages, at the first moment the diff is sollicited, as if there was a loose somewhere. And what makes it even weird is that it doens't happen all the time...
I will keep you updated on what they find on friday.
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      09-24-2012, 04:19 PM   #8
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OK keep us updated.
Pay attention to the noise/feel. If it starts to get worse, just be safe and stop driving.
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      09-25-2012, 06:46 AM   #9
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My car does have some similar symptoms, and I noticed them just after I installed the Cobb (which has much more low-end torque compared to my former GIAC S2 tune).

When I floor the car at 1800RPM in a higher gear (4+, but mostly in 6th) after the boost comes on I hear some "hurrr" sound coming from the back, for approximately 1-2 seconds and then it disappears as the RPM climbs. It may be from the diff, from the axles or maybe from the exhaust, I am not sure. Maybe even from the driveshaft ? I have a Drexler LSD and it did not give me any problems, and not even now, it works perfectly on the road and at the track, except at this "test". I will check the parts when I will install my new clutch in about a week.

Given the fact that I did participate at some drag racing evens, I am thinking that it can be from the axle joins or something. I will check them out in about a week.
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      09-25-2012, 08:16 AM   #10
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Quote:
Originally Posted by cstavaru View Post
My car does have some similar symptoms, and I noticed them just after I installed the Cobb (which has much more low-end torque compared to my former GIAC S2 tune).

When I floor the car at 1800RPM in a higher gear (4+, but mostly in 6th) after the boost comes on I hear some "hurrr" sound coming from the back, for approximately 1-2 seconds and then it disappears as the RPM climbs. It may be from the diff, from the axles or maybe from the exhaust, I am not sure. Maybe even from the driveshaft ? I have a Drexler LSD and it did not give me any problems, and not even now, it works perfectly on the road and at the track, except at this "test". I will check the parts when I will install my new clutch in about a week.

Given the fact that I did participate at some drag racing evens, I am thinking that it can be from the axle joins or something. I will check them out in about a week.
FWIW, I wouldn't load up the car in high gear at 1,800 RPM. The "hurr" might be your engine protesting. Just sayin'.
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      09-25-2012, 08:56 AM   #11
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FWIW, I wouldn't load up the car in high gear at 1,800 RPM. The "hurr" might be your engine protesting. Just sayin'.
It may very well be, and the engine sound could reach the exhaust. No codes thrown though, and the car runs fine. Not sure what it is, really. It does sound a lot like a horrible exhaust drone but it's not quite drone. Especially given the fact that it only appeared after installing Cobb (Stage 2+ Aggressive)...
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      09-25-2012, 09:11 AM   #12
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I blew up the diff on my 335 about 8 months ago. Gigantic bang on a hard shift into second gear. The car was almost undriveable in 2nd after that.

The dealer diagnosed the problem as passenger side axle bushing that seized and caused trammeling along the rear end, thus breaking diff. Fixed under warranty.
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      09-27-2012, 12:59 PM   #13
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Quote:
Originally Posted by cstavaru View Post
It may very well be, and the engine sound could reach the exhaust. No codes thrown though, and the car runs fine. Not sure what it is, really. It does sound a lot like a horrible exhaust drone but it's not quite drone. Especially given the fact that it only appeared after installing Cobb (Stage 2+ Aggressive)...
I'm just saying that going WOT at that low of an RPM is definitely not good for your engine in any way. Personally, I never go WOT under 3,000 RPM unless I'm doing datalogs. Just good practice

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Originally Posted by bigdaddycane View Post
I blew up the diff on my 335 about 8 months ago. Gigantic bang on a hard shift into second gear. The car was almost undriveable in 2nd after that.

The dealer diagnosed the problem as passenger side axle bushing that seized and caused trammeling along the rear end, thus breaking diff. Fixed under warranty.
Wow...surprised at that...
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      09-30-2012, 04:22 PM   #14
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So went to the dealer last friday, they think the problem is the transfer case, so it will be replaced under warranty. Hopefully I still have a warranty, because the tranfer case itself is 5200$ + tax + 6 hours job...
I hope this fixes my problem!
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      09-30-2012, 04:54 PM   #15
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Quote:
Originally Posted by Quebequer
So went to the dealer last friday, they think the problem is the transfer case, so it will be replaced under warranty. Hopefully I still have a warranty, because the tranfer case itself is 5200$ + tax + 6 hours job...
I hope this fixes my problem!
Which dealer?? I replaced my TC but had a 4x4 malfunction, ABS & DSC codes everywhere....and had only rwd, so maybe it's not TC??!!!
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      09-30-2012, 06:35 PM   #16
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Dealer in Quebec city, bmw ville de québec. I don't know if it's really TC, but it cannot hurt to have a brand new one at 53K miles!
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      09-30-2012, 10:03 PM   #17
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See if you can get the old TC back, or at least find out exactly what broke. The AWD guys are trying to figure out how to strengthen the AWD drivetrain so it can handle more power, and we could use some info.
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      09-30-2012, 10:18 PM   #18
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See if you can get the old TC back, or at least find out exactly what broke. The AWD guys are trying to figure out how to strengthen the AWD drivetrain so it can handle more power, and we could use some info.
I will try to find out. The only problem is that the dealer do not open it. They send it back to bmw. That's what I was told but I'll see what I can do.
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      10-01-2012, 09:29 AM   #19
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I will try to find out. The only problem is that the dealer do not open it. They send it back to bmw. That's what I was told but I'll see what I can do.
In the US by law the shop must return all parts to the owner if requested. Im not sure if this applies to warranty work as well.
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      10-01-2012, 11:32 AM   #20
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In the US by law the shop must return all parts to the owner if requested. Im not sure if this applies to warranty work as well.
Same law here in Canada, but since I do not pay for the job, I think it does not apply. I will try to find out.
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      10-01-2012, 01:25 PM   #21
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Same law here in Canada, but since I do not pay for the job, I think it does not apply. I will try to find out.
Amazing - how did you get warranty work done when your car is FBO?
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      10-01-2012, 01:35 PM   #22
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No, been there done it, BMW has a return process for the gearbox and diff. BMW local engineers do not open these item but swap them for new/refirb items.

Pricing is based on the above..... Even worse, if they detect that a 3rd persion has opened the box/diff, you might even end up with an higher price as BMW might not accept the return... That's why most dealers do not install LSD's...
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