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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 Mon, Feb-20-2017, 10:00:22 AM   #21
schoonerm3
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Default Re: Lateral play in Input flange

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Originally Posted by TheCoder View Post
Thanks. It seems like it was under tightened as evident by the fact that i needed little force to release the nut , but i couldnt do so with my bare hands either.


I am concerned about any damage to the pinion or ring gears, so will empty the diff fluid and check for discoloration or metal parts stuck to the magnetic drain plug .

Ia the torque range you provided what is needed to move the entire unit with or without the diff fluid ? With or without the output axle attached ?


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It will be without fluid and without axles. It's somewhere in that range anyway so do some research first. It's a very specific torque wrench to measure that low torque. You would need a larger one to measure with axles and fluid. Maybe 70 inch pounds range.
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Old Tue, Feb-21-2017, 04:56:14 PM   #22
nowanker
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Default Re: Lateral play in Input flange

My $.02: If you no longer have any play, are up above 100lb to tighten it, and beyond your original mark, don't go any farther! The crush sleeve height determines pinion bearing preload, and distorting it further will just increase that. Don't bother to back it off from where you are now, the 'crush' is permanent. It won't spring back but merely reintroduce the play. Changing the crush sleeve basically involves rebuilding the diff.
It's either:
A) OK where it is now, or slightly too tight... if the bearings make noise later, rebuild it then
B) Too tight, time for rebuild sooner instead of later
or C) Not tight enough, and needs another turn to bring it to the mark. You can always tighten it more... but never less! And you would probably be able to feel the play from 1 turn of looseness by hand.
If it's too loose, you can always tighten it another round. If it's too tight, you'll be rebuilding it. The diff will let you know when!
GL!
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Old Sun, Feb-26-2017, 04:32:09 AM   #23
TheCoder
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Default Re: Lateral play in Input flange

So this is what I have done today.

1. I tightened the nut as close as I could to the original mark. I think I didn't tighten it correctly before as I don't recall having to use that much force. I'm as close as I can get to the original mark now with the limited space I have under the vehicle. There is no way I added an extra revolution as I stated earlier because the previous revolution had low torque measurement (as in I reached it manually).



2. I drained the diff fluid. I think I made the right choice by using a magnetic drain plug as that allowed me to notice if any metal was actually damaged. I noticed a thick layer of black material which I reckon is iron particles from the wear on the diff. The problem is that I can not assess if this was due to the under tightening or not because I didn't flush the fluid when I changed it 4 months ago (Because it's so freaking expensive!) .




However, I found one thing stuck to the magnetic drain plug. a tiny cylindical metal piece. The shape and size doesn't make sense. it is approx 1mm in length and 0.1 mm in width. I don't know if it came from inside the diff, or something that the magnetic drain plug caught to before I installed it 4 months go. I can't really see how could it have came from the pinion, ring or bearing! I did a lot of research on diff internal parts and cant make the link. So I am assuming it's something the magnet caught before installation.




3. I used an endoscope to check the pinion. I didn't notice any damage to the pinion or pinion gears. So I think I am good there.

4. The Diff fluid that I drained was darker compared to fresh fluid. Again, I didn't flush the diff last time because the diff fluid is expensive, so I can't really use this as conclusive indication of anything.



5. measure rotating torque. The lowest I measurement I can go with my ft lb wrench was 5, and it didn't click. Gonna get an inch lb torque and measure the rotating torque just to be safe.


Anyway, I'll reassemble everything , put new diff fluid , and run the car while keeping an ear for any whine coming from the diff.
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Old Sun, Feb-26-2017, 04:34:01 AM   #24
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Default Re: Lateral play in Input flange

Quote:
Originally Posted by nowanker View Post
My $.02: If you no longer have any play, are up above 100lb to tighten it, and beyond your original mark, don't go any farther! The crush sleeve height determines pinion bearing preload, and distorting it further will just increase that. Don't bother to back it off from where you are now, the 'crush' is permanent. It won't spring back but merely reintroduce the play. Changing the crush sleeve basically involves rebuilding the diff.
It's either:
A) OK where it is now, or slightly too tight... if the bearings make noise later, rebuild it then
B) Too tight, time for rebuild sooner instead of later
or C) Not tight enough, and needs another turn to bring it to the mark. You can always tighten it more... but never less! And you would probably be able to feel the play from 1 turn of looseness by hand.
If it's too loose, you can always tighten it another round. If it's too tight, you'll be rebuilding it. The diff will let you know when!
GL!


Yea, I think I'll be following your advice. In theory I should not have a problem since the nut and pinion are marked. But if I am screwed then I'll find out soon enough.
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Old Mon, Feb-27-2017, 11:18:23 PM   #25
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Default Re: Lateral play in Input flange

Good luck, let us know how it turns out.
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Old Sun, Mar-05-2017, 10:49:27 PM   #26
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Default Re: Lateral play at Input flange

So i have put everything back. Putting the nut on the mark required a lot of torque. But its done.

The backlash is minimal now. And the m clunk is gone. I cant hear anny whining fron the diff when i drove the car, but then again, i drove it with the muffler not installed so it was loud.

Ill update the status as soon as i get the muffler back and drive the vehicle for longer distances.

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Old Sun, Mar-19-2017, 07:36:32 PM   #27
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Default Re: Lateral play in Input flange

Closing the loop on this topic. Vehicle is running just fine, no issues in the past 15 days, no m clunk. Moving on to new challenges.

Thank you all for your feedback.
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Old Tue, Mar-21-2017, 03:50:30 PM   #28
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Default Re: Lateral play in Input flange

Congrats on the save!
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Discussing Lateral play in Input flange 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)