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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Sun, Sep-09-2018, 09:20:03 PM   #21
e36 323ti
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Default Re: E46 M3 Diff (my journey)...

Changed my CV. The new ungreased one (sorry for vertical video):



... and installled:



Big difference from the old one. No more "clank".

Still some clunk. Next will be to replace the drive shafts...
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Old Sun, Sep-09-2018, 10:22:24 PM   #22
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Default Re: E46 M3 Diff (my journey)...

Everything you are showing is completely normal for any car. The difference with the E46 M3 diff is the shorter passenger side output flange allowing radial play. This is just the way it is. All of the videos showing rotational clunking, especially when making your movements from the output side is NORMAL... every car does this.
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Old Mon, Sep-10-2018, 02:54:41 AM   #23
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Default Re: E46 M3 Diff (my journey)...

If you install poly diff bushings it will sound like rear end is ready to blow off the car, takes some getting used to, but is normal, per Braymond.

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'85 528e 164k miles (sold)
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All DIY: 330 ZHP steering rack, diffsonline 4.1 diff with rem polish, E60 short shifter lever, AKG black diff bushings/subframe bushings, Rogue rtab, WPC rod bearings, Beyer driveshaft, full SS (SS stepped V1, catted S1, resonated S2, SS sport), Sachs clutch/flywheel, rear main, VANOS bullet proofing with anti-rattle, valve adjustment, cooling refresh, Ohlins R&T/Swift 448f 672r/GC street tops and camber plates, AFD E85 Proflex kit.

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Old Mon, Sep-10-2018, 03:53:51 AM   #24
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Default Re: E46 M3 Diff (my journey)...

Quote:
Originally Posted by mrgizmo04 View Post
If you install poly diff bushings it will sound like rear end is ready to blow off the car, takes some getting used to, but is normal, per Braymond.

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Try solid diff bushings A friend if mine did that and Would never do that to my car....
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Old Mon, Sep-10-2018, 08:08:31 AM   #25
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Default Re: E46 M3 Diff (my journey)...

Quote:
Originally Posted by Braymond141 View Post
Everything you are showing is completely normal for any car. The difference with the E46 M3 diff is the shorter passenger side output flange allowing radial play. This is just the way it is. All of the videos showing rotational clunking, especially when making your movements from the output side is NORMAL... every car does this.
As stated in the opening post: " As most E46 M3 owners, my cars does have some sort of e46 M3 diff clunk. Not sure if mine is the "normal" clunk, since it is extensive and quite loud. A "lot" of play in both output flanges as well as in the input flange."

Everyone is claiming that a m3 clunk is normal. Should have some clunk. But what is normal? How much is some? How loud is normal?

Being an engineer, I prefer real numbers and measurements as well as to understand why it is "normal".

In the TSB we can find some numbers. I measured on both the old and the brand new diff, and while the old was within the TSB numbers, the new had (naturally) less play.

The old CV slide very easily off the drive shaft, whilst the new one had to be "pressed" in. The old CV had clearly lost some of the lubricant, exposing the balls in the bearing and possibly some of the damping effect of the "ring" covering the balls in the bearing. Maybe a re-lubrication would have helped on the clank, since the video of the new one clearly demonstrates where the clank sound is coming from?

What I have shown could very well be "normal", and that changing the parts that I have done is unnecessary.

On the other side it is also clear that:
-With the new diff on the car, the clunk was reduced, but not zero.
-With the new CV in place, there are no noticeably clank when driving the car.
-Still some clunk from the drive shafts. Are going to refurbish them.
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Old Mon, Sep-10-2018, 08:36:42 AM   #26
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Default Re: E46 M3 Diff (my journey)...

For an engineer who is looking for real numbers and measurements, "clunk was reduced" and "clank is not noticeable" does not help either . Decibels?

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All DIY: 330 ZHP steering rack, diffsonline 4.1 diff with rem polish, E60 short shifter lever, AKG black diff bushings/subframe bushings, Rogue rtab, WPC rod bearings, Beyer driveshaft, full SS (SS stepped V1, catted S1, resonated S2, SS sport), Sachs clutch/flywheel, rear main, VANOS bullet proofing with anti-rattle, valve adjustment, cooling refresh, Ohlins R&T/Swift 448f 672r/GC street tops and camber plates, AFD E85 Proflex kit.

Happy to help with VANOS or any other DIY job around NorCal
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Old Mon, Sep-10-2018, 11:41:26 AM   #27
e36 323ti
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Default Re: E46 M3 Diff (my journey)...

Quote:
Originally Posted by mrgizmo04 View Post
For an engineer who is looking for real numbers and measurements, "clunk was reduced" and "clank is not noticeable" does not help either . Decibels?

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The hypothesis is that there is a relationship between play and "clunk"/"clank", right?

Ideally: dB would have been the preferred measurement to document the changes in the sound, but it requires some special equipment.

Practically: The videos should illustrate/document the effect of the changes where pure dB measurements are missing

Edit 1: On another note, it should be possible to extract the sound track from the video and send it through some DSP sw. Think I have to try that...

Edit 2: Extracted the sound track from the video with the old diff and old CV as well as from the new diff and new CV. Clearly different PSDs


Last edited by e36 323ti; Mon, Sep-10-2018 at 05:08:33 PM. Reason: Update
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Old Mon, Sep-10-2018, 06:47:15 PM   #28
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Default Re: E46 M3 Diff (my journey)...

Have a Diffsonline rebuilt Dinan 3.91 LSD. It clunks worse and it whines. But racecarl.
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Old Mon, Sep-10-2018, 08:17:34 PM   #29
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Default Re: E46 M3 Diff (my journey)...

Quote:
Originally Posted by e36 323ti View Post
Had the first drive with the new diff. Definitely less Clunk, but the Clank is still there. Next step will be to replace the "constant velocity joint"...

Edit: Good post for the Clank: http://www.m3forum.net/m3forum/showthread.php?t=369047
The CV joint is a good call. I replaced the whole propshaft because you get all the joints in one.

The prop is an interesting design. It has almost every joint known to man.

Rubber coupling, UJ, Ball race and a CV on the end!

Is your front diff rubber mount ok?
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Old Mon, Sep-10-2018, 08:36:58 PM   #30
e36 323ti
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Default Re: E46 M3 Diff (my journey)...

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Is your front diff rubber mount ok?
Yes, the front diff rubber mount looks ok.
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Discussing E46 M3 Diff (my journey)... in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)