2005 E53 Clunk from rear end??

[E533.0i]

Hello to all,I'm new to bmws for the most part.I recently purchased a 2005 e53 x5 with the 3.0i engine and automatic transmission.I got the car cheap because It needed a rear diff.Which was surprising considering the car only has 82k miles on it.Now I put in a rebuilt rear diff.My wife has been driving the car for the past 2 or 3 months.This is her daily driver.I drove the car recently and noticed that shifting into reverse and giving it throttle there is a clunk.My driveway is on a hill.So then the load change.Once backed up and shifting into drive and giving it throttle another clunk.

It seems as though when the load change occurs I hear a clunk definitely from the rear of the car.This only happens on inclines or sloped surfaces.The last time is happened the 4x4 light came on and stayed on.

I am a master tech by trade and have been working for audi for the past 12 years.I havent had the chance to inspect the car since I heard the noise.But Im just curious if anyone has experienced any other problems beside the rear diff??

It is possible the rebuilt rear diff is no good.But I would assume it would do it all the time??Another possibility is the transfer case??Or chain possibly??But then I would hear that from the center of the car and I would assume I would have abs and brake lights lit on the instrument cluster??I was able to pull codes recently but the scan tool I was using was very limited.Just told me the codes not very detailed.

Engine:
P111F Intake Air Temperature Sensor 1 Minimum Temperature Implausible (Bank 1)

Not really concerned with this one we'll see if it comes back.

P3199 Engine Coolant Temperature Signal Stuck

Possibly faulty coolant temp switch??

The engine fault i'll address if they return.As they were pending.

I had 4 fault stored I believe in the transmission.

Transmission/DSC faults:

5EB1 Steering-angle sensor, supply
Posssibly lost signal??or faulty steering angle sensor i heard is common??

5DD2 - DSC: Control unit, overvoltage
Not sure on this one if its related to the 4x4 light on not given the faults below.

5F42 - Transmission control Limp mode operation
I am not sure if i cleared all the faults after the original diff failed.Possible it an old fault.Not really sure.

5DEC -Also could be an old fault not sure.Ill have to check if it returns.However could be related to VTG motor or wrong rear diff the car??

55C4 - I saw a TSB that says its possible the transfer case is fault if this fault code is stored.I guess I'll have to recheck and possibly pick up a factory level scanner.






Just looking to see what else could be the issue besides the obvious faulty rebuilt rear diff.

[David.X5]

Similar sounds have been associated with stripped out splines on the front driveshaft and/or stretched transfer case chain. Have someone walk along next to the car to try and narrow down the location of the sound. I don't think you can tell very well from inside the car.

Option #2 is the rear subframe bushings. They generate a rear clunk when worn. There are threads here and a couple of people/places you can rent the special tool to pull the old bushings out to replace them. It's not too big a job - a few hours with the special tool.

[E533.0i]

Thanks for your input.I am wondering if it could the stripped out spline on the front driveshaft as I know the vehicle was driven even after the rear diff failed,esecially dragging the rear end because it had no drive to the rear wheels.I will have to look and see.If there a way to tell if the splines are stripped without removing the drive shaft??

[David.X5]

I don't know of a way to inspect the front drive shaft splines without removing it. The good news is that a stock front drive shaft will come out without removing the front diff or transfer case. Unbolt the front guibo and then slide the driveshaft forward until the splines are free. You may not need to even take it all the way out - once you can see most of the spline, you should be able to tell if they are worn/messed up or not.

Make sure you have the wheels chocked before you disconnect the drive shaft!

[E533.0i]

Thanks I wount need to once I have it on the lift.But thanks for the heads up.

[srmmmm]

If your drive shaft splines are worn, the vehicle won't move. There's no "slippage" capability. There is either enough steel to be engaged, or there isn't. I would apply the parking brake, place the transmission in neutral and turn the rear driveshaft by hand to check for excessive play in one of the u-joints. I'd also inspect the differential mounts since it was replaced as well.

2002 X5 3.0 293,100 miles
2014 428i 14,600 miles

2004 325i sold at 123,600 miles
2001 325i sold at 66,000 miles

[David.X5]

I agree the front splines can't fully slip until it is toast, but my experience, and others, report hearing "clunk" or other metallic sounds going from reverse to drive before that point. When I had that problem, and removed the front driveshaft, I found the teeth were about half sheared off, giving it a few degrees of wiggle when changing direction.

[David.X5]

Fwiw, Here's a picture of my almost-sheared-off front driveshaft spline next to the replacement long spline version.

[bcredliner]

This also always happens on a level surface when you shift from reverse to drive back and forth at an idle?

[SunnyDaze]

Resurrecting this. My '03 E53 with 188k is doing the "clunk" when putting it in drive (sometimes) or reverse (more often). It's more pronounced when on a grade. It's most pronounced when backing up an inclined curve. It also does the "clunk" when going from drive to park facing downhill.

FWIW, rear subframe bushings and most suspension parts are <1 year old.

Did you ever figure out the culprit / solution?