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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 Fri, Apr-13-2018, 07:30:19 AM   #21
rovert604
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Default Subframe surprise

I had that issue just like OP. But I caught those after we welded all the major stuff right at the subframe mounting points. I had extensive cracks that were large and made their way several inches.

If you have a buddy to help you stop drill and weld, then the extra time it takes to get at the cracks shouldn’t be that time consuming. We did the welding to seal up all my damage and it didn’t take much time to fix up. The most time was spent epoxy sealing everything up and waiting for it to dry/cure. You really want good coverage to protect from water and rust.

The wheel well edges were coming apart on one side of my car. The sheet metal is really thin there and you’ll want to grind away a lot of the sealant because the heat transfer is fast and starts to light the sealant on fire. LOL. We just took our time on that part to create minimal heat by zapping opposite sides until all was joined.

You can drive your car but keep throttle control smooth and ginger. Accelerate like you’re a Toyota Corolla with one spark plug not working. lol. Whatever cracks that have formed, will just start to keep getting bigger as your rear diff twists the subframe upon throttle and engine braking. You’ll need to use more welding material to seal the tears and possibly end up with more stop drills throughout. Get the fix done as soon as you can and don’t wait too long.

Because of where your sheet metal is separating, you’ll want to make sure that is very very well dried out if you continue to drive it in wet conditions. You’re asking for rust to happen if it is not 100% dry before welding the separation shut.

Good luck!
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Old Fri, Apr-13-2018, 02:51:44 PM   #22
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Default Re: Subframe surprise

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Originally Posted by Kleedzine View Post
any reinforcement done before this crack?
No reinforcement performed. I'm getting ready to do it in a few months. The subframe mounts are clean of cracks.
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Old Mon, Apr-16-2018, 03:15:52 PM   #23
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Default Re: Subframe surprise

Update:

Got the car on the lift. Rear left wheel well has a separation of 6-8". Trunk on the driver side has slight creasing from the RACP movement, and there is a significant crack in the right to the right of the rear left mount.

More extensive than I thought after all was cleaned up and inspected.
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Old Mon, Apr-16-2018, 03:54:54 PM   #24
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Default Re: Subframe surprise

Wow, doesn't sound good at all. All the best with the repair!
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Old Mon, Apr-16-2018, 04:59:01 PM   #25
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Default Re: Subframe surprise

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Originally Posted by Kdubski View Post
Update:



Got the car on the lift. Rear left wheel well has a separation of 6-8". Trunk on the driver side has slight creasing from the RACP movement, and there is a significant crack in the right to the right of the rear left mount.



More extensive than I thought after all was cleaned up and inspected.


Thats not good at all, are you still planing to attend the Ax in Mass next weekend?


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Old Mon, Apr-16-2018, 05:19:59 PM   #26
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Default Re: Subframe surprise

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Originally Posted by Radekxpl View Post
Thats not good at all, are you still planing to attend the Ax in Mass next weekend?


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No autox or driving until this is fixed. Will probably start the work in 2-3 weeks.
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Old Tue, Apr-17-2018, 04:28:33 AM   #27
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Default Re: Subframe surprise

Just got mine back from Redish Motorsport they do a thorough inspection and this video might help you identify exactly where they suffer cracks


Nearly all cars have some form of cracks or spot welds go
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Old Tue, Apr-17-2018, 05:03:20 AM   #28
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Default Re: Subframe surprise

Identical to mine. Stripped it down and stiched the arch.
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Old Tue, Apr-17-2018, 06:08:47 AM   #29
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Default Re: Subframe surprise

My car already has plates welded in, but this makes me want to get an x-brace to really tie up the rear.
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Old Tue, Apr-17-2018, 07:11:18 AM   #30
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Default Re: Subframe surprise

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Originally Posted by M3_Pilot View Post
My car already has plates welded in, but this makes me want to get an x-brace to really tie up the rear.
Plates only move the load to the next weak link, the wheel arches. Get a brace.
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Discussing Subframe surprise 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)