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535xi passenger axle and housing broke

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Old 07-26-2019, 05:37 AM
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I'm not saying there's no way. OP already said he was able to slide the axle far enough into the hub for the nut to thread on and not need any tools. I had to use the puller as there was no way the splined shaft was going farther into the hub than having the threads 20mm deep in the hub. No way to thread a not on it, and nothing behind to push it farther. I had lightly greased clean splines before assembly, and Bentley just says push it in and tighten the nut, but if it were that easy every time, why would the tool be made? Removal required considerable force using a threaded press tool and it fought all the way out. I've never been a fan of beating on an axle stub due to risk of munging the threads or damaging the wheel bearing.

Last edited by audiophool; 07-26-2019 at 05:39 AM.
Old 07-26-2019, 08:45 AM
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Thank you @audiophool for sharing the info, I certainly want to be prepared in every way possible before I start my job next week.
Old 07-26-2019, 02:32 PM
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i didnt grease the threads, just the splines. getting the original one out, i took the nut off and put it back on a couple threads and hit it w a dead blow so no damaging the threads. can also put the nut on a few threads amd use a drift or something that will fit inside the part of the nut sticking out since its only on by a couple-few threads and hit that to punch it out wo damaging the threads. spray w pb blaster if it seems rusty, which it prob will be. clean the splines in the hub and lightly grease, lightly grease the splines on the axle, i had no prob gettin it on wo a tool. one time it wasnt comin thru far enough i jus pushed in o nthe rotor and it came through far enough to get the nut started.

when you take your axle out, can you please measure it for me? relaxed and compressed? that would be huge for me if you could.
Old 07-26-2019, 02:51 PM
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Originally Posted by jadidaskv
when you take your axle out, can you please measure it for me? relaxed and compressed? that would be huge for me if you could.
Are you measuring from tip to tip, or any other point on the axle? Can't say I've tried measuring one before, but I'm assuming you want overall length.
Old 07-27-2019, 05:46 PM
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Originally Posted by kd7iwp
Are you measuring from tip to tip, or any other point on the axle? Can't say I've tried measuring one before, but I'm assuming you want overall length.
yes exactly. tip to tip/overall length
Old 08-03-2019, 11:53 AM
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Took my axle shaft out today. I hope these are what you’re looking for. Looks to be roughly 38.5” normally and 40.25” stretched.


Old 01-21-2020, 03:23 PM
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Hello jadidaskv
Any update?
I have been dealing the front passenger axle for a bit on 535xi sedan. I have replaced two front passenger axles with GKN brand which is OEM to BMW in 12K miles. On both of them I have experienced same symptoms. The grease leaks out of the inner boot only right above the control arm. Outer boot does not have any leaks, but seems stretched. There are no tears in the boot that I can see.

Also the both inner and outer boots seems collapsed as if the air is sucked out of them. I wonder if the axles are pulled more than usual, causing the boot to stretch as in the picture? Could the axle be slightly shorter?

The car seems to be driving fine with no vibrations. I measured the front tire distance to compare it to the rear. Rear are about 3/4" wider.

Here is a thread I started...

https://5series.net/forums/e60-discu...2/#post1603690

Any thoughts...
Thank you
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