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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Technical Forums > DIY Guides > DIY: Front Output Flange Replacement



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      06-20-2015, 05:20 PM   #1
bhmax16
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DIY: Front Output Flange Replacement

Hey guys, I replaced my front output flange last night because I discovered some wear on it when replacing some bearings in my transfer case last weekend. I figured I'd write up a quick DIY on it for those that are interested. Replacement is simple so I'm going to make this short and sweet.

Tools needed:
Prybar
Rubber mallet
Seal puller

This DIY should be used in conjunction with others in this forum for changing your transfer case fluid and pulling the front driveshaft.

This is what we start with:


After draining your transfer case fluid and removing the front driveshaft, use a prybar and pry on the output flange as shown. A small slide hammer would also work here, but my cv axle puller attachment was too small to fit:


This is the flange removed from the transfer case:


Notice the wear/scouring on the flange:



Use a seal puller to pull out the old seal (or your fingers if you're the hulk):


Here is a shot of one of the bearings I replaced in the transfer case last weekend. BMW does not sell any internal parts for our transfer cases, but you can get the bearings from Cobra Transmission:


Use a seal driver to drive the new seal flush with the transfer case. I like to use a little RTV on the outer edge to ensure a good seal:



Apply anti-seize to the splines of the new flange (BMW provides this with purchase of the flange). Press the flange into the transfer case until you can't push it any further, then slightly rotate to align the splines. Once you are aligned, use a rubber mallet to drive the flange all the way into the transfer case.



Now attach your front driveshaft and fill your transfer case with the proper fluid (it takes about 0.6 quarts). Reattach any plastic shielding under the vehicle that was removed for access.

Go for a spin, or have yourself a cold one of your favorite brew.
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      06-23-2015, 03:50 PM   #2
ajaye
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Nice. What lead you to the bearing replacement to begin with, did you have a code(s) or failure? Just curious. Thanks for the DIY.
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      06-24-2015, 12:40 PM   #3
bhmax16
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The bearing replacement was due to noise when not under load, especially on the highway. If I was cruising around 70mph, then let off the throttle, I would get a loud rumbling sound. Similar to what you'd experience with a differential with too much backlash, but it was clearly a bearing noise. I diagnosed the front output shaft bearings by grabbing the front driveshaft and wiggling it (I had nearly 1/8 inch of play at the flange). I confirmed these bearings were the issue when I pulled the front driveshaft (effectively making the car rwd and eliminating load from the bearings) and the noise disappeared.

Cobra Transmission is the only source of the bearings to my knowledge. BMW sells no internal parts for our transfer cases, which is asinine. $80 for two bearings and 5 hours of my time and I was back on the road again, vs $2500 for a rebuilt transfer case through BMW. Replacing the bearings was the clear choice.
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      06-24-2015, 04:55 PM   #4
ajaye
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Quote:
Originally Posted by bhmax16 View Post
BMW sells no internal parts for our transfer cases, which is asinine.
Unless you are BMW!

Nice work, thanks again for the info.
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      06-27-2016, 10:58 PM   #5
ericnk
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good job man

how long did the job take you and how did you take it out. did you use a pry bar ?
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