2005 X5 4.4 right front axle install problem

[pghguy517]

Hi, In the middle of replacing the alternator bracket seal, but ran into a problem when reinserting the right front axle into the differential.
I can engage the first part of the axle splines up to what I believe is the spring clip, but can't get past this point. I've tried pushing and tapping to get past the spring clip, but it won't go in. I've hit it much harder than a tap a bunch of times, but no luck. I'm worried that something will break, especially since the differential is mounted to the side of the cast aluminum oil pan.
Also, when removing the axle front differential, I had to hit it hard to remove. But I've hit it even harder to install, and no luck.
Any suggestions? Thanks

[CapeX5]

make sure you are rotating it while pushing or using "persuasion". You want the slots of the splines to line up and it should slip in. I just installed mine on saturday and had to give them a good knock. I used a long pry bar though and put it on the flat parts of the axle where it meets up to the oil pan. Hard to describe but you will see them.

[4.8isX5]

You need someone to hold it level and push on it torward the way it needs to pop in while you take a mini sledge and long sturdy flathead and tap on it. If it doesnt want to go in, disengage, rotate a few times and try again. I couldnt get it past the clip on my own till i had someone do that.

If you dont have someone put pressure on it and push it mostly rebounds off.

[keduMINI]

Originally Posted by 4.8isX5

You need someone to hold it level and push on it toward the way it needs to pop in while you take a mini sledge

I am in agreement with this statement above.

I rigged up a contraption comprising a 8 gallon bucket (30 L) covered with a stack of 2 X 4 inch wood blocks whose lengths were greater than the bucket diameter.

This was done to balance the axle horizontally against a combination of the car frame and wood blocks. (see pdf attachment for general idea)

Work the splines into alignment by hand (the axle will penetrate about 0.5 to 1 cm within differential).

I was able to keep constant inward pressure (ie boots compressed) on the axle shaft by bracing a 2 X 4 board against the floor and axle (see pdf). The inward pressure kept the axle straight whilst hammering on the 2 X 4 lever with a mini sledge hammer (very deliberate swings). Occasionally the axle will lose its alignment at the joints because of an off-center hammer strike, but you will be making progress.

Realign and continue with very focused hammer strikes until the circlip seats

I also use some moly grease on the splines.

[X5only]

I was in the same predicament while doing the exact same thing as you, but I gave up after much struggle and fear I'd mess up the splines or something. Others input are spot on, and how do I know? I had my vehicle towed to an Indy shop and $120 later, all was well and the mechanic said all I had to do was make sure to align the axle real good while pushing in - naturally, easier said than done! I made an insurance claim for the towing (insurance rate never went up). Not dissuading you from trying, but just an option to consider and save yourself much angst.

[pghguy517]

Thanks all! I was really concerned that something was wrong and preventing the axle from going in, so I pulled the front differential loose so I could check the axle splined end and spring clip. All was good, put it back together but came up with new plan to force the axle in and over-ride the spring clip retainer.
A 3" exhaust clamp fits the grooves of the inner axle collar very nice, clamp just tight enough to get a positive grip on the axle to hammer on. As hard as I was hitting on the grooves, the pry bar, punch-chisel, or whatever would easily slip off. With the clamp, you can use one hand to hold the axle straight and provide firm inward pressure, while the other presses on the clamp with an air chisel with blunt end. This worked like a champ, just make sure to do this in a controlled manner and stop the air chisel once you get past the initial snap ring tension.