BMW X5: Removing And Installing/Replacing Rear Differential

Special tools required:

• 33 5 120
• 33 5 122
• 33 5 125
• 33 5 200
• 33 5 206

WARNING: Danger of injury! Rear differential must be lashed with tightening strap 33 5 206 to prevent it falling out when the output shafts are forced off.

Necessary preliminary tasks:

• Remove propeller shaft on rear differential.

Position special tool 33 5 200 on workshop jack.

Support rear differential with special tool 33 5 200.

Lash rear differential with tightening strap 33 5 206 to special tool 33 5 200.

IMPORTANT: Tightening strap 33 5 206 must be pass through between output shafts and rear differential cover!

Fig. 16: Identifying Special Tool (33 5 200) And (33 5 206)

IMPORTANT: Risk of damage! To prevent the rubber mounts from overstretching when the bolts are pulled out, ensure the bolts remains in the rubber mounts.

Release screws (1).

Installation:

Adhere to the installation sequence at the end of the document in order to prevent distortion of the rear differential during installation and thereby avoid potential complaints about noise.

Fig. 17: Identifying Screws

Release nut and remove bolt (1) towards front.

Installation:

Adhere to the installation sequence at the end of the document in order to prevent distortion of the rear differential during installation and thereby avoid potential complaints about noise.

Fig. 18: Identifying Bolt

IMPORTANT: Risk of damage! Output shafts must not under any circumstances rest on swinging arms.

Tape off output shafts or place a cloth on swinging arm.

Lower rear differential slowly with aid of workshop jack and press to one side.

Fig. 19: Identifying Output Shafts

IMPORTANT: Special tools 33 5 120 and 33 5 125 must be inserted in all round slot (1) on output shaft!

Fig. 20: Identifying All-Round Slot On Output Shaft

Press output shaft by jerks and jolts with special tool 33 5 120 out of rear differential. Here, thrust piece of bolt 33 5 122 must rest on rear differential.

Fig. 21: Identifying Special Tools (33 5 120) And (33 5 122)

IMPORTANT: In order to ensure correct locking of the output shaft in the rear differential, make sure when driving in the output shaft that the tightening strap 33 5 206 is not located between the rear differential and the dust plate!

Installation:

Drive output shaft with special tool 33 5 125 and a rubber mallet into rear differential.

Fig. 22: Identifying Special Tools (33 5 125) And (33 5 206)

Feed output shaft out of rear differential and tie up.

Installation:

Replace shaft seal(s) for output shaft(s).

Fig. 23: Identifying Output Shaft Of Rear Differential

IMPORTANT: High installation forces indicate that the output shaft spline teeth are damaged or deformed!

Installation:

Check spline teeth, replaced damaged parts if necessary.

Check dust plate (1) for damage, replace if necessary.

Replace retaining ring (2).

Coat highlighted contact surface (3) of output shaft with approved rear differential oil.

Fig. 24: Identifying Dust Plate, Retaining Ring And Contact Surface

Installation:

Insert output shaft into rear differential.

Pull out assembly protection ring at lug (1) until one of the two programmed rupture points gives.

Fig. 25: Identifying Ring At Lug

NOTE: Repeat procedure on the other side, remove rear differential with a second person helping from special tool and set down on a suitable surface.

Installation sequence:

1. Install rear differential with workshop lifter and special tool 33 5 200 in rear axle carrier.

2. Insert bolts (1) (do not tighten down).

3. Insert bolt from rear and replace nut (2) (do not tighten down).

4. Release tightening strap, lower special tool 33 5 200 and move away.

5. Tighten down bolts (1).

Tightening torque.

6. Tighten nut (2).

Tightening torque.

Fig. 26: Identifying Bolts And Nut

After installation:

• Check rear differential oil level , correct if necessary.

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