My 2004 E53 (3.0d) lost propulsion suddenly about 3 weeks ago just as I was about to leave on a business trip. On my return, I went through the process of elimination and came up with the rear differential as being the culprit.
Being the hands on type, I proceeded to remove the differential with the help of a buddy and stripped it down.
I really didn't expect what I saw next...........
Please see photos -
Photo #1 shows the ruined shaft minus the tip. Note the partial spiral shape of the splines.
Photo #2 shows the unaffected shaft.
Photo #3 shows the two shafts removed from the differential housing. Note the tip of the shaft sitting to the left.
I would love to know if this has happened on any other E53 3.0d and whether or not it is the torque of this monster that caused it.