Picked up a seized engine E70 (N55)

[BergA]

Well, today was the day! I reinstalled the engine on Saturday, and on Sunday reinstalled the transfer case, electronics, intake manifold, power steering and A/C, radiators, front bumper, and drive axles. More posts to follow about the transfer case install, but for now I'll share this:

https://www.youtube.com/watch?v=ql6CsCPH3_U

One issue is I have an airbag light, and indicator stating the passenger side airbag has an error. From a few minutes of googling it seem like I need to read/clear the code with INPA. It may have been caused by a low battery condition.

[bawareca]

Originally Posted by BergA

One issue is I have an airbag light, and indicator stating the passenger side airbag has an error. From a few minutes of googling it seem like I need to read/clear the code with INPA. It may have been caused by a low battery condition.

It is confusing for most folks(me too), but it actually says "Fault in passenger restraint system" and it means the restrain system for all passengers in the vehicle(including driver) and not "Passenger side restraint system"
Good job on the repair and congrats on the resurrected engine There is a chance that you pulled the axle too much when removing it and it was almost fallen apart when you installed it. Should be able to put it back together.

[BergA]

Originally Posted by bawareca

There is a chance that you pulled the axle too much when removing it and it was almost fallen apart when you installed it. Should be able to put it back together.

I've been thinking more about it and I think you're exactly right. You can even see on the first page of this thread, the boot on the shorter (driver's side) has a kink in it that I simply couldn't remove. I think this indicates a vacuum was generated when I over-extended the joint.

So hopefully it didn't get too beaten up during the towing process and I can reassemble it. I drove probably 150 feet total.

[BergA]

Getting back to engine installation, I wanted to share my procedure because it improved greatly from the first time.

This time around, I used a much better method of installing the engine and transfer case. I did not unbolt the subframe at all! Fortunately there is enough space above the transmission in the frame cavity that by lifting the engine/transmission high enough, you can clear the power steering rack.

After the engine was installed and bolted to the bellhousing/transmission, I went about installing the front transfer case. I looped a zip tie through the rear output disk and through the front upper bolt hole. Then I looped a ratchet strap through those zip ties and lifted the entire assembly with the engine crane. Then I slowly and carefully maneuvered it into place singlehandedly. Since the engine crane was in-use, I lifted the engine below the oil pan using a floor jack.

The final pic is of the BMW getting towed him after the drive axle failure.

[BergA]

Originally Posted by bawareca

There is a chance that you pulled the axle too much when removing it and it was almost fallen apart when you installed it. Should be able to put it back together.

That was the project for tonight. I began by removing the driver's side front drive axle just as I had the first time. Once I had it on the bench, the fun began. Both the inner and outer joints felt funny so I serviced both of them. I worked on the outer joint first, the one with the 6 captured balls inside. I found vise grips to work well for removing one type of clamp-band. The internal components were completely covered in grease so I ultrasonic cleaned everything as best I could. The end of the spline which contacts the center pinion was fairly chewed up and the pinion would no longer slide on. Using a triangular jeweler's file, I carefully filed the teeth smooth until the pinion slid on. Once that was repaired, I used a tiny amount of grease to get the internal components back into place. Next I tapped the splined shaft into the pinion and seated the circlip.