BMW Cars 1999-06

Halfshaft

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CV Boot Clamp Installation



The CV-boot clamps can be one of three types, a folding double clamped band, a double loop band, or an ear clamp band. The folding double clamped band has thick curved portion of band that seats into a small bracket and applies tension as the curved portion is pressed downward, and held in place by two folding tabs. The double loop band wraps around the CV-boot twice and through a small clip. The ear clamp band has a series of holes and locking tabs that are locked into the holes.

  1. To install a folding double clamped band:
    1. Seat the end of the thick curved section into the small bracket.
    2.  
    3. Press the thick curved section down, flush with the band.
    4.  
    5. While holding the curved section down, fold over the locking tabs and seat them by tapping them lightly with a small hammer.
    6.  

  2.  
  3. To install a double loop band CV-boot clamp proceed as follows:
    1. Install the clamp in the direction such that if the axle were installed on the vehicle the clip of the clamp is at the top, with the end of the clamp is facing forward.
    2.  
    3. Wrap the clamp around the boot 2 times, and seat the clamp into the groove of the boot.
    4.  
    5. Pull the end of the clamp by hand to remove any slack in the band, and scribe a mark in the band 1 / 2 an inch (12mm) from the clip.
    6.  
    7. Using a boot band tool or an equivalent device, pull the end of the clamp until the line is flush with the rear edge of the clip, and then fold the end of the clamp upward so it is at a 90° angle with the clip.
    8.  
    9. While holding the end of the clamp in this position, center punch the clip using a pointed center punch and a hammer.
    10.  
    11. Trim the end of the clamp 3 / 8 of an inch (10mm) from the end of the clip, fold the clamp end over the clip and seat the folded clamp end by tapping it with a hammer.
    12.  

  4.  
  5. To install an ear clamp style band clamp proceed as follows:
    1. Feed the tab of the band into the holes of the band. Sometimes a small flat-bladed jewelers screwdriver can be placed through the clamp's hole and the tab levered into place.
    2.  
    3. Squeeze the small raised ear portion at the base of the clamp using a pair of boot band pinchers, or carefully alternate side to side with a thin pair of needle nose pliers, until the gap at the base of the clamp's ear is 1 / 8 of an inch (3mm) apart.
    4.  

  6.  

CV-Joint Overhaul



The replacement CV-boot clamps can be one of three types, a folding double clamped band, a double loop band, or an ear clamp band. Do not substitute ordinary radiator hose clamps or plastic ties in place of a CV-boot clamp.


CAUTION
When replacing a CV-joint or CV-boot, do not reuse the CV-boot clamps.


WARNING
When removing a CV-joint, make sure to matchmark all the components before disassembly to ensure the components are installed exactly in the same location from which they were removed. If a component is to be replaced, make sure to install the replacement part in the exact location as the component being replaced. Failure to reinstall the components correctly could result in premature failure or excessive driveline vibration.

If a CV-boot has failed and is to be replaced, the CV-joint from where the failed boot was located must be cleaned and repacked with the appropriate lubricant.

When the outer CV-boot is to be replaced and/or the outer CV-joint serviced, if special tools are not available to remove the outer CV-joint, simply disassemble and remove the inner CV-joint and boot, then slide the outer boot off of the axle.


WARNING
If the outer CV-joint is to be replaced, make sure to note whether or not the vehicle is equipped with ABS brakes to ensure the correct replacement parts.

Due to the popularity of halfshafts on front wheel drive and four wheel drive vehicles, axle and halfshaft rebuilding facilities have become increasingly popular. Before removing and disassembling a halfshaft, check locally to see if there is a facility available that will sell a rebuilt halfshaft, or rebuild your halfshaft. You may discover that this is more cost effective and convenient, especially if you remove the halfshaft yourself.

  1. Remove the halfshaft assembly.
  2.  
  3. Remove the inner CV-boot clamp, then remove the boot plate from the inner CV-joint. Remove the snapring from the axle, matchmark axle to the CV joint, then slide the CV joint off the axle assembly, then the inner boot.
  4.  


NOTE
It may be necessary to use a small universal gear puller to remove the axle from the CV joint.

  1. Clean the axle shaft and apply a light lubricant to ease the boot removal.
  2.  
  3. Remove the clamps from the outer CV joint and slide the boot off the axle.
  4.  



Click image to see an enlarged view

Fig. Use a 2 inch (50mm) wide spatula to pack the outer CV-joint assembly with an approved CV-joint grease



Click image to see an enlarged view

Fig. The ear band CV-boot clamp is assembled by placing the tabs through the holes in the clamp



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Fig. The ear band CV-boot clamp is tensioned by squeezing the base of the ears together using a boot band pincher

To install:

  1. Thoroughly clean and inspect the CV joints for looseness, signs of overheating or damage and replace as necessary.
  2.  
  3. Inspect the CV boots for tears, cracking or hardening and replace as necessary.
  4.  
  5. Using a small flat spatula or scraper, carefully pack the outer CV joint with an approved high temperature CV joint grease.
  6.  
  7. Wrap the end of the axle splines with vinyl tape to prevent damage to the boots. Install the outboard boot along with it's clamps. Make sure to at least slide the small clamps on at this time.
  8.  
  9. Install the inner boot.
  10.  
  11. Remove the vinyl tape, align the matchmarks and install the inner CV joint along with a new snapring onto the axle.
  12.  
  13. Secure the CV joint boot clamps on the outer CV, but only install the large clamp on the inner CV joint at this time.
  14.  
  15. Carefully slide a small flat-bladed screwdriver between the axle and the unclamped small end of the inner CV boot to allow air to escape while packing the CV joint with grease.
  16.  
  17. Using a small flat spatula or scraper, carefully pack the inner CV joint with an approved high temperature CV joint grease.
  18.  
  19. Once properly packed with grease, secure the small CV joint boot clamp on the inner CV.
  20.  

Removal & Installation



3-Series
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Rear tire and wheel assembly
     
    Output shaft at the outer flange and suspend it
     
    Caliper, and suspend it with the brake line connected. Unbolt and remove the rear disc.
     
    Large nut and lock plate. If equipped with ABS, disconnect, then remove the ABS speed sensor.
     
    Collar nut. Then, remove the drive flange with a suitable press tool or install the collar nut until it is just flush with the end of the shaft and use a suitable soft faced hammer to knock out the shaft.
     
    Snapring. Pull out the wheel bearings, using a suitable tool.
     

  4.  
  5. Pull the inner bearing race off the axle shaft with tool No. 00-7-500.
  6.  

To install:

  1. Install or connect the following:

    New bearing assembly, using suitable bearing driver tools. Install the snapring.
     
    Rear axle shaft with tool Nos.: 23-1-300, 33-4-080 and 33-4-020 or their equivalents.
     
    Collar nut, after lubricating, and drive in the lock plate using a suitable tool. Collar nut: 148 ft. lbs. (200 Nm).
     
    ABS speed sensor
     
    Brake disc and caliper
     
    Output shaft
     
    Rear tire and wheel assembly

    Click image to see an enlarged view

    Fig. Remove the snapring from the hub-3-Series



    Click image to see an enlarged view

    Fig. Tool No. 00-7-500 bearing puller used to remove the inner bearing race-3-Series

     

  2.  

5 & 7-Series


Click image to see an enlarged view

Fig. Cut-away schematic of the rear halfshaft and suspension system-5 Series

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Rear tire and wheel assembly
     
    Lock plate and if equipped, the ABS sensor
     
    Retaining nut from the output flange
     
    Flange
     
    Output half shaft from the final drive (differential carrier) by pressing out with a suitable tool and suspend it
     
    Output shaft from the drive flange hub using a suitable tool
     
    Rear axle shaft with a suitable tool
     
    Snapring
     
    Pull out the wheel bearings, using a suitable tool
     
    Pull out the seal with a suitable tool
     

  4.  
  5. If the inner bearing shell is damaged, pull it off with a suitable puller and thrust pad.
  6.  

To install:

  1. Using an appropriate bearing installer, install the wheel bearing assembly, then install the seal, and insert the snapring, then install the rear axle shaft, all in reverse of the removal procedure.
  2.  
  3. Install or connect the following:

    Axle shaft seal
     
    Output shaft, as follows: screw the threaded spindle into the shaft all the way, then use the nut and washer against the outside of the bridge
     
    Output shaft to the final drive. Mounting bolts: 42-46 ft. lbs. (58-63 Nm).
     
    Outer nut, bearing surface lubricated. Nut: 169-188 ft. lbs. (234-260 Nm).
     
    ABS sensor, if removed
     
    Rear tire and wheel assembly
     

  4.  

E30 Models
  1. Remove the rear wheel. Pull out the lockplate and remove the axle nut.
  2.  
  3. Remove the constant velocity joint bolts at the final drive output flange.
  4.  
  5. Use Tool No. 33 2 110 or equivalent to press the axle through the bearing and out of the vehicle. Do not allow halfshaft to drop.
  6.  

To install:

  1. Place the halfshaft through the bearing and pull into place using Tool No. 33 2 110 or equivalent.
  2.  
  3. Secure the constant velocity joint bolts at the final drive output flange and torque to 42 ft. lbs. (58 Nm).
  4.  
  5. Lubricate the axle nut with oil. Torque the axle nut to 145 ft. lbs. (200 Nm) and install the lockplate with Tool Nos. 33 4 050 and 00 5 500 or equivalent. Install the rear wheel.
  6.  

E36 Models
  1. Remove the rear wheel. Remove the rear exhaust system at the rear axle. Disconnect the stabilizer bar and move down. Remove the ABS sensor. Pull out the lockplate and remove the axle nut by installing two lug bolts and using a long, suitable prytool to hold the axle while loosening the stub axle nut using a 1 / 2 drive 12 point 30mm (1 3 / 16 inch socket and a suitable breaker bar. These sockets are readily available from the Sear® mail order tool catalog.
  2.  
  3. Remove the constant velocity joint bolts at the final drive output flange, which typically are removed with an E12 inverted Torx® socket.
  4.  
  5. Use Tool No. 33 2 110 or equivalent to press the axle through the bearing and out of the vehicle. Do not allow halfshaft to drop.
  6.  

To install:

  1. Place the halfshaft through the bearing and pull into place using Tool No. 33 2 110 or equivalent.
  2.  
  3. Secure the constant velocity joint bolts at the final drive output flange and torque to 42 ft. lbs. (58 Nm).
  4.  
  5. Lubricate the axle nut with oil. Torque the axle nut to according to the thread spindle size, which typically on 3 series is size M22, and if used, install the lockplate with Tool Nos. 33 4 050 and 00 5 500 or equivalent, otherwise stake the nut.
    1. Following are the rear axle spindle nut tightening specifications:

      M22 spindle: 147.5 ft. lbs. (200 Nm)
       
      M24 spindle: 184 ft. lbs. (250 Nm)
       
      M27 spindle: 221 ft. lbs. (300 Nm)
       

    2.  

  6.  
  7. Install the ABS sensor, the stabilizer bar and the exhaust system. Install the rear wheel.
  8.  



Click image to see an enlarged view

Fig. Install two lug bolts and use a long, suitable prytool to hold the axle when loosening the CV joint to output flange fasteners



Click image to see an enlarged view

Fig. Loosen the inner CV fasteners. Typically the fasteners are removed using an inverted size E12 Torx® socket



Click image to see an enlarged view

Fig. Once the axle is removed from the final drive, lower it and support it with mechanic's wire



Click image to see an enlarged view

Fig. The stub axle splines are likely to have been installed with a locking agent. A press tool is used to press the axle out of the hub



Click image to see an enlarged view

Fig. Once the stub axle is loose, it can be pressed out using a suitable drift and a hammer



Click image to see an enlarged view

Fig. Cut the mechanic's wire and . . .



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Fig. . . . withdraw the axle from the vehicle



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Fig. The ABS exciter ring is part of the stub axle. If replacing the stub axle make sure the exciter ring is not damaged



Click image to see an enlarged view

Fig. Note the build up of debris on the stub axle. If available . . .



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Fig. . . . carefully clean the metal surfaces of the stub axle. Avoid contact with cleaning solvents on the rubber CV boots



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Fig. Clean the stub axle splines with a small wire brush



Click image to see an enlarged view

Fig. Always use a torque wrench when installing the axle fasteners



Click image to see an enlarged view

Fig. Mount the wheel with the center cap removed for removal and installation of the spindle nut which requires using a 12 point 30mm socket

 
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