[tmick5jr]

is that a washer behind the new clip you installed? my clip fell off but i don't see a washer there behind it. do i need one?

[bleicht]

Wow, thanks for posting this up. This is exactly what happened to me on my 2008 pre-LCI (125k miles) RWD E90.

I would have thought it was impossible to replace but I did it. I had to pull the forward downpipe back and was able to replace the clip using a mirror, this homemade tool, and patience.

I made the tool out of some plastic tubing I had lying around from some other project. I made a few versions using a Dremel to shape it and cut a slot to hold the clip. On the final version, I used "blue tak" or "fun tak" to hold the clip in the slot a little bettter. This is the gray clay type stuff that kids use to put posters up on the wall without using thumbtacks. You can buy it at a craft or office store.

Good luck! I sure hope I don't have to do this again.

[danfratamico]

I attempted this using E-clips of different sizes. They were imperial sizes so I was bouncing between a 3/16" and a 1/8". The 1/8" was way too small and 3/16" was a tad large, so I crimped it a little with pliers. This was impossible to get on and it kept on dropping. FYI, I didn't move anything out of the way.

Since my rod is 6 mm, I ordered two of part "11657606506". I too have a question if we need a washer or not. Seems like there is enough gap for one and without adding a washer, there will still be lots of play.

From what I observed, since my wastegate shaft has become oval over time, I can see that due to the ovalness, as the shaft rocks left to right, that is putting a lot of pressure on the E-clip, and will most likely cause it to fall off. I'm assuming either that's what happened to my existing E-clip or it just melted off due to the heat.

[bleicht]

I think the root cause of these clips coming off is that the WG flapper starts to bind on high mileage turbos. I replaced my turbos a 6 months after replacing the clip...they were shot.