E53 rear differential output drive flange
 

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...........:yikes:

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.

:wow::wow::wow::wow:

Haven't seen that on the X5 before. Is your vehicle chipped, out of interest?

:dunno:As far as I know everything is stock. I have had my X5 for almost three years now and there's nothing to suggest that it's was chipped by the previous owner.
I suspect that the tip of the shaft snapped but the splines continued to be engaged for a bit longer. This shows from the wear on the exposed surface.

Is this from an auto or manual?
I’ve seen this type of failure before but not on an X5 and not twisted to the degree this one is.
It’s usually caused by a combination of a manual gearbox and being abused; eg dropping the clutch at a high RPM, etc.
Not to say that you have been abusing it but it may have been abused before you purchased it and it’s just failed now.

If it’s an auto then I have no idea, perhaps it’s just a substandard part that hasn’t been hardened properly.

Hello JDD,
My X5 is basially the same as yours. Auto/steptronic, 3.0d turbo, 18" wheels, all stock equipment.
I haven't abused it in the almost 3 years that I've had it and I doubt very much that the somewhat elderly gentleman, from whom I bought it, had either the time or inclination the put it through those paces. :D
:iagree:I am inclined to agree with you on the idea that the material was in someway not properly hardened. It's my only logical guess:dunno:
I have since ordered and received two new pieces and shall proceed to rebuild the differential ASAP.
Thanks for the questions and ideas. I love the learning process!