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#1
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Help - New Front driveshaft not going in
Any tips on getting new shaft back in? 6 cyl 2001. I have the trans support off. ![]() ![]() ![]()
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Kevin 2001 X5 3.0i Phoenix, AZ Last edited by ewebby; 06-20-2022 at 10:48 AM. |
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#2
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I recently did something very similar. If the length of the entire shaft has been increased by 1", the transfer case needs to be removed to install the shaft. Very drastic. I ended up cutting a half inch off of mine and having it rebalanced to avoid that. Another option would be to have a half inch shorter in total shaft, with the properly lengthened splines, and add a spacer where it bolts to the guibo to properly mesh the splines. I didn't bother with that.
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- 2011 BMW X5 x35i - 2005 BMW X5 4.4i - 2005 BMW X5 3.0i - 2004 BMW X5 4.4i |
#3
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Get a set of needle files from Harbor Freight and find the one that most closely matches the spline. Relieve the burrs so the shaft goes in easier. Don't go crazy. I had a similar problem more than once on various axle shafts on BMW and Audi and this worked every time. Don't whack it with a mallet either. Finesse is your friend...
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2001 x5 3.0, 1990 e30 M3, 1991 318is, 2002 325i, 2008 335i Dinan stage 3 6 speed, |
#4
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thanks
I have filed the grooves with a needle file and wire brush. I think I am hitting the stripped part of the upper groove and hitting the groove, I may need to twist clockwise after I insert while holding the transfer case female.
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Kevin 2001 X5 3.0i Phoenix, AZ |
#5
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talked to bmw tech that sold this on ebay and I just need to file like you said. half moon then square file in the groove. I am hitting the broken section of the splines. It is supposed to go in fairly easily as they test with a broken one before shipping. Wish me luck
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Kevin 2001 X5 3.0i Phoenix, AZ |
#6
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I have a used "as taken from service" transfer case if everything hits the wall.
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2001 x5 3.0, 1990 e30 M3, 1991 318is, 2002 325i, 2008 335i Dinan stage 3 6 speed, |
#7
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I ended up giving up trying to get it into my old transfer case, I bought a new shaft and rebuilt transfer case from https://www.tcbmwx5.com/
check your splines, if they look like mine above, you need a transfer case. 4 hours of filing did not work due to the first inch of splines were half broken off and the torque kinda bent them, no way to get it in. 4 days of trying and figured with 260k prob worth it to get a rebuilt. Plan on keeping car for another 5 years so will see.
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Kevin 2001 X5 3.0i Phoenix, AZ |
#8
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I ended up giving up trying to get it into my old transfer case, I bought a new shaft and rebuilt transfer case from https://www.tcbmwx5.com/
check your splines, if they look like mine above, you need a transfer case. 4 hours of filing did not work due to the first inch of splines were half broken off and the torque kinda bent them, no way to get it in. 4 days of trying and figured with 260k prob worth it to get a rebuilt. Plan on keeping car for another 5 years so will see. after filing for 4+ hours with small flat and square files. ![]()
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Kevin 2001 X5 3.0i Phoenix, AZ |
#9
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On your first pictures the splines don't look like bent but just worn out. Did you try to file the beginning of the shaft side splines a bit sharper (especially the side facing the worn side on transfer case)? I know this would lose a minor bit of effective length but could guide the splines past the egde of the worn part.
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E39 530dA -02 M-Sport Messing metallic E53 X5 3.0dA -06 Sport Stratus grey |
#10
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yes I tried to file down but that steel is very hard. not worth the time to work in a hot AZ garage, just punted. Thought about just cutting off the first inch of the female lol.
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Kevin 2001 X5 3.0i Phoenix, AZ Last edited by ewebby; 06-23-2022 at 02:26 PM. |
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