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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 Tue, Aug-07-2018, 05:34:22 PM   #11
mrgizmo04
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Default Re: E46 M3 Diff (my journey)...

Quote:
Originally Posted by rbg View Post
My diffsonline has clunk. I asked them to make it as tight as possible so clunk is way less than it was before. However there is a price for tighter assembly it whines more than stock when you of throttle at 60-80mph.
Yep, mine is tight and with poly bushings all around it whines...

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All DIY: VANOS, WPC rod bearings, full SS (SS stepped V1 headers, catted S1, stock S2, SS sport), AFD E85 Proflex kit, Ohlins R&T/Hyperco 375f Swift 672r/GC street tops and camber plates, ST40 355 pfc08, 330 ZHP steering rack, diffsonline 4.1 diff with rem polish, E60 short shifter lever, AKG black diff bushings/subframe bushings, Rogue rtab, Sachs clutch/flywheel, rear main, Beyer driveshaft, valve adjustment, cooling refresh.

Happy to help with VANOS or any other DIY job around NorCal. Have various specialty tools (VANOS, RTAB, engine bar, valve adjustment, tranny jack, ball joint separator, pilot bearing puller, tap&die kit, etc).
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Old Tue, Aug-07-2018, 11:01:10 PM   #12
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Default Re: E46 M3 Diff (my journey)...

My clunk was getting progressively worse, took it in Monday for evaluation and was given 2 options. 1 replace upper bushings and center section with alignment $5200. Option 2 upper bushings and rear cover to correct leak $800. I chose option 2, picked up car this evening and it is now as smooth as my 2014 F150 or the 2018 Mazda 3 I had for a rental.
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Old Wed, Aug-08-2018, 12:44:58 AM   #13
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Default Re: E46 M3 Diff (my journey)...

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Originally Posted by DNS2003M3 View Post
My clunk was getting progressively worse, took it in Monday for evaluation and was given 2 options. 1 replace upper bushings and center section with alignment $5200. Option 2 upper bushings and rear cover to correct leak $800. I chose option 2, picked up car this evening and it is now as smooth as my 2014 F150 or the 2018 Mazda 3 I had for a rental.


$800 for rear cover replacement, thatís a real steal


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Old Wed, Aug-08-2018, 01:13:53 PM   #14
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Default Re: E46 M3 Diff (my journey)...

My first E46 back in 2003 clunked from day one, I bought it pretty much new with about 3k miles on it. My second and current E46 had some seepage in the diff when I bought it, it was literally the only thing that came back on the PPI, it also had the typical clunk. So I replaced it with a Dinan performance diff and it does not clunk.
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Old Wed, Aug-08-2018, 09:43:23 PM   #15
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Default Re: E46 M3 Diff (my journey)...

New diff in, but first some doc of the old one...

The old diff had much more play on the right (passenger) side than the new (the new had virtually 0 play), but less on the driver side than the new. Seems like the play was tuned around comparing the new and the old. The largest play on the old one was ~2mm (1mm on the new).

Video of the old diff (with the Clunk?):


Probably nothing wrong with the old diff...

Learnt that we have to distinguish between the e46 m3 Clunk and the Clank.

With the diff out, it was kind of clear that my car had at least the Clank (which I believed was the famous Clunk).

Video of the Clank (sorry for the vertical video):

Last edited by e36 323ti; Sun, Aug-12-2018 at 05:01:27 PM.
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Old Thu, Aug-09-2018, 06:44:41 AM   #16
e36 323ti
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Default Re: E46 M3 Diff (my journey)...

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

Last edited by e36 323ti; Thu, Aug-09-2018 at 05:23:59 PM.
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Old Thu, Aug-09-2018, 11:30:11 AM   #17
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Default Re: E46 M3 Diff (my journey)...

I've been going through the same thing and noticed that my inner CV joints are pretty sloppy so I think that is part of the problem. Has anyone found a good source for CV joint replacements other than the $600 OE shafts?
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Old Thu, Aug-09-2018, 11:49:21 AM   #18
Obioban
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Default Re: E46 M3 Diff (my journey)...

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I've been going through the same thing and noticed that my inner CV joints are pretty sloppy so I think that is part of the problem. Has anyone found a good source for CV joint replacements other than the $600 OE shafts?
BMW sells it without the shaft.

https://www.realoem.com/bmw/enUS/sho...diagId=26_0197

26117841003
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Old Sun, Aug-12-2018, 05:26:05 PM   #19
e36 323ti
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Default Re: E46 M3 Diff (my journey)...

The measured rotational play in both diffs:



EDIT: Added TSB info..

TSB: E46 M3 - "Clunk Noise" on Load Reversal
MODEL :E46 M3 with S54 engine

SITUATION
Customer may complain of a drivetrain rattle or knocking noise during a load change, e.g. 1st to 2nd gearshift at low engine speed, coming from the rear axle area. Further drivetrain checks reveal that the right side rear axle output flange appears to have more play (approximately 0.5mm to almost 1mm) when compared to the left side output flange.

INFORMATION
The radial play on the right side rear axle flange is a normal design characteristic of the new M differential lock style rear axle used on E46 M3 models. Therefore an M3 differential should not be replaced due to a difference in play (when comparing left to right side differential output flange play) since this will not eliminate a drivetrain rattle or knocking noise.

IMPORTANT
In order to transmit engine torque to the rear wheels instantaneously, without any time lag, the whole M3 power train was designed with maximum torsional rigidity. Consequently, the flywheel mass and its damping capability has been reduced to a minimum. As a result, during an abrupt torque transfer (e.g. 1st to 2nd gearshift at low engine speeds) driver receives an acoustic feedback, which can be interpreted as a "clunking or rattling" noise. This characteristic is common in many high performance vehicles. Activation of the "Sport Mode" offers an additional increase in driving dynamics. As a result, acoustic feedback from the power train may be even more pronounced. The acoustic feedback characteristic is not a symptom of a failure, and does not compromise long-term reliability of drivetrain components (clutch, transmission, differential), nor does it adversely affect performance of the vehicle.

WARRANTY INFORMATION
For information only.

From <http://www.m3forum.net/m3forum/showthread.php?t=379846>

Last edited by e36 323ti; Sun, Aug-19-2018 at 11:56:31 AM.
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Old Sun, Aug-12-2018, 07:07:36 PM   #20
ctres
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Default Re: E46 M3 Diff (my journey)...

Quote:
Originally Posted by Obioban View Post
BMW sells it without the shaft.

https://www.realoem.com/bmw/enUS/sho...diagId=26_0197

26117841003
Sorry, meant the CV joints on the axles, not the driveshaft.
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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)