[leegibson84]

Hi,
I have a 2007 328xi that has a stripped trans output spline to the transfer case. I am wondering if this spline can be removed without opening up the trans. Please check out the pics and let me know what you think. If you see the part on the realoem web page it leads you to believe you should be able to pull it right out. There was a bolt on the end of the spline that I have removed but still I am not able to pull it out. I wonder if the rear main seal is holding it in? Look at part #11
Anyone have experience with this?
Thanks
Lee

[leegibson84]

anyone??

[kiel_dafo_kenyg_as]

I only can offer you my thoughts (no experience here) and a better drawing.
Did you remove the bolt #13? It should be an M10 x 95 millimeters (~4'')
There's another spline profile inside the output axle. You should be able to pull it apart here.
This may require some force and the need of a pull-off tool. To help the puller getting a grip you may want to weld a thick washer plate to the shaft stub. Then screw back in the #13 bolt and stop 3-4 turns before it's flush. Then use the puller and see if it moves.
The outer shaft may be glued to the inner shaft. Pulling right after welding helps with some good benefit from expanding effects and also softening glue.

[kiel_dafo_kenyg_as]

Originally Posted by leegibson84

anyone??

If you only have the time to ask but then refuse to keep us posted the answer seems to be No

[critical05]

Since its an adapter shaft, most likely its an interference fit spline, a press fit pilot or taper fit somewhere. They'll do this to minimize tolerance stack up for runout.

If there's no good shoulder for a puller of some sort, you could try to heat the shaft to cause it to expand. Since the shaft is junk anyways, you could drill and tap the existing hole on the shaft to something larger. Then you would a have a jack hole screw you can use a bolt that would push the shaft off, just be carefull its not damaging the threads on the inner shaft. This is just suggestions going off of the limited knowledge I have about the assembly of it.

[freebo86]

I know this a long shot and old thread, but has anyone else encountered this issue and addressed? I just found the same issue with my X3 and trying to figure out how to remove the old shaft.

There is no shoulder on it to use a jaw puller, even if there was the jaw puller would be pushing against it while trying to pull it out so it becomes counter intuitive.

Hope to hear some thoughts!

[freebo86]

To provide an update for anyone who encounters this issue in the future as it appears to be somewhat common. I found a youtube video of another guy having the same issue. Did not find anywhere how to remove it tho. This adapter shaft applies to;

• 3' E90   (02/2004 — 08/2008)
• 3' E90 LCI   (05/2008 — 12/2011)
• 3' E91   (03/2004 — 08/2008)
• 3' E91 LCI   (05/2008 — 05/2012)
• 3' E92   (06/2005 — 02/2010)
• 3' E92 LCI   (09/2009 — 06/2013)
• 5' E60   (07/2004 — 02/2007)
• 5' E60 LCI   (11/2005 — 12/2009)
• 5' E61   (09/2004 — 02/2007)
• 5' E61 LCI   (11/2005 — 05/2010)
• X3 E83   (05/2003 — 07/2006)
• X3 E83 LCI   (02/2006 — 08/2010)
• X5 E53   (08/1999 — 09/2006)

Youtube video I found.

Below is the tool I rigged up using a 2" bearing separator and some 3/8s threaded rod and 1/4" plates to allow the unit to come out. There is a small shoulder right where the spline end that the bearing puller can get a good grip on that allows it to be driven out.

And these are the official BMW instructions how to pull it off and calls for a special tool, $100. https://we.tl/t-NkS284RNPF

[PhaseP]

From the visible and abundant fine red rust dust, these are cases of "fretting". There was minute amount of relative motion at the interface of the metal parts, could be initially even very small. This starts eating into each other generating the very fine red iron oxide dust as they keep doing so.

https://en.wikipedia.org/wiki/Fretting

Heavy moly grease applied at the spline interfaces may help from this to reoccurring, or delay it much further to occur.

[freebo86]

Originally Posted by PhaseP

From the visible and abundant fine red rust dust, these are cases of "fretting". There was minute amount of relative motion at the interface of the metal parts, could be initially even very small. This starts eating into each other generating the very fine red iron oxide dust as they keep doing so.

https://en.wikipedia.org/wiki/Fretting

Heavy moly grease applied at the spline interfaces may help from this to reoccurring, or delay it much further to occur.

Would you recommend moly grease over like an anti seize compound to prevent this?

[PhaseP]

http://files.danfoss.com/documents/L1310978.pdf