Quote:
Originally Posted by Henn28
Thats a strange one for sure. Sounds like the PO may have had the same problem and had to re-seat the axle as well. Could the axle joint(s) have failed in some way?
Short of that, my guess would be a failing front diff, or I wonder if it is possible for a failing tcase or front driveshaft splines to vibrate badly enough to pop the axle out of the diff.
I'd start with the easy and move to the difficult as you rule stuff out. I seem to recall your car will drive without the front driveshaft? If so maybe pull the front driveshaft first, check the splines and if they (and the Tcase splines) look good then take it for a drive in 2 WD mode. No vibration would narrow it down while vibration remaining would certainly point to the axle or diff in my view.
I'm afraid none of it's easy, but the front diff in my view would be the most challenging by far. Motor has to come up a few inches and the subframe needs to come down a few inches. It also weighs a ton so getting it back in laying on your back is fun, and I'm not sure there is a rebuild kit for it. PM me if it comes to this as I just had mine out of my 2002 E53 4.4.
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When I pull fuse #46 to get it to rwd or 2wd, the sound and vibrations are gone, to pull the front drive shaft I need to remove the t-case since its the electric t-case (xdrive) with the shorter drive shaft, I did read some information about removing the guibo then the shaft, but that was for the pre-facelift models, currently I couldn't do that until summer anyways due to -30 degree weather.
Good point on the vibration causing the axle to pop out! It entirely could have been, we have owned the car for 6 -7 months and the sound/vibration only started 3 days ago. I do believe the axle popped out before the sound started though, I dont daily drive it so I couldn't say for sure.
From what you said though, it may seem that it is the t-case, it's a good point that driving it in rwd mode and the sound stops, which it does, technically the axles are still spinning the diff and crown ring, just not the pinion and drive shaft, therefore the only non moving part would be the t-case, the front driveshaft and or diff pinion, right?
Without removing the t-case/drive shaft what would be a good way to diagnose further?
Thank you for your input!