1998 BMW 540i 331

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331-2
Final Drive
This repair group covers removal and repair informat~on for
the final drive (differential), axle shafts.
CV joints, CV joint
boots, and final drive seal replacement.
Internal repairs of the differential assembly are not covered in
this manual.
Special tools
BMW recommends some special tools for the removal of the
drive axles as well as the installation of rear differential input
and output drive flange seals. Some common pullers and
drifts can often be substituted for these tools.
4 Drive flange holder
(Tool No. BMW
2 30 020)
< Drive flange puller
(ToolNo.BMW31 2101 131 2102131 2103131 2104)
< Drive pinion set
(Tool No. BMW 33 1 340)
4 Clamp~ng tool set
(ToolNo.BMW332101 13321021332103)

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Final Drive
4 Output shaft tool set
(ToolNo.
BMW332111 1332114/332115/3321161
33211713321181332119)
4 Trailing arm tool set
11 (Tool NO BMW 33 3 331 I 33 3 332 1 33 3 333 133 3 334)
4 Final drive mount set
(ToolNo.
BMW334151 /334152/334153/334154/
3341551334156133415713341581334159)
< Differential mount press set
(Tool
No.BMW334161 1334162133416413341651
33 4 166)
33 4 161
Q Differential mount press set
(ToolNo.
BMW334171 /334172/334173/3341 174)
. .
33 4 181 4 Differential mount press set
33 (Tool No. BMW334181 133418213341831334184)
Support tube set
(ToolNo.BMW334191133419213341931334194)
33 4 192
33 4 191

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331-4
Final Drive
4 Final drive output shaft seal tool
(Tool No.
BMW 33 4 250)
4 Pulling set
(Tool No.
BMW 33 4 401 / 33 4 402 / 33 4 403 133 4 404 /
33 4 405 / 33 4 406)
Aluminum suspension components
In order to reduce vehicle weight, aluminum suspension com-
ponents are
~sed in some models. A tesl wlh a magnet wi.1
eas'ly reveal lhe metal Lseo. If working with a umin~m com-
ponents, be sure to read and follow the cautions below.
CAUTIOI\C
Due to the chemical and corrosion characteristics of alumi-
num, do not bring into contact with battery acid.
Do not use wire brushes with brass or iron bristles.
Only use brushes with stainless steel bristles.
Do not expose to flying sparks from grinding/cutting op-
erations.
Do not subject to steel welding splashes.
Do not expose to temperatures over
80°C (176"F),
even for short periods. Temperatures in painting facili-
ties are not a problem.

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331-9
Final Drive
Coat drive flange sealing area and seal lip with differential oil.
* Install drive flange on pinion shaft.
Using
BMW special tools 23 1 300,33 1 341 and 23 1 302
press drive flange on to pinion shaft only to extent as to al-
low collar nut to be installed.
4 Tighten collar nut only until previously marked points are
aligned (arrow).
CAUTION-
Do not underany circumstances tighten collarnut beyond the
markedpoints,
othe~lise clamping sleeve will have to be re-
placed.
- Using a suitable drift, install new collar nut locking plate
Stalte plate in place.
- Remainder of installation is reverse of removal.
- Check and, if necessary, set differential oil level. See Differ-
ential oil level, checking.
Tightening torque Driveshaft
CV joint to final drive flange
MI0 (Torx bolt) 70 Nrn (51 ft-lb)
ME (compression nut) 32 Nrn (24 ft-lb)

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331-1 1
Final rive(
< Coat seal with differential oil and drive into place using BMW
special tools 00 5 500 and 33 4 250 or equivalent.
Replace snap ring (arrow) on final drive output flange shaft.
Coat output flange
shaft with differential oil where it con-
tacts shaft seal.
. Push output flange into final drive until flange splines en-
gage splines of differential gear and snap ring can be
heard to snap into place.
- Remainder of installation is reverse of removal.
Check and, if necessary, set differential oil level. See Dif-
ferential oil level, checking.
Tightening torques Drive axle to final drive flange
Torx bolts
(M10) 83 Nm (61 ft-lb)
Torx bolt with ribbed teeth (M10) 64 Nm (47 it-lb)
Torx bolt with ribbed teeth (Mi0 silver) 80 Nm (59 ft-lb)
Torx bolt with ribbed teeth (MI0 black) 100 Nm (74 ft-lb)
- Torx bolt with ribbed teeth (M12) 135 Nm (100 ft-lb)

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331-12
Final Drive Final drive cover, removing and installing
- Remove final drive. See Final drive, removing and install-
ing.
I 1 4 Remove fasteners (arrows) from rear cover and remove cov-
er.
Clean cover and final drive housing sealing surfaces.
Install new
gasket with cover.
* Installation is reverse of removal.
- Check differential oil level. See Differential oil level, check-
ing.
Tightening
torque
Final drive cover to final drive housing
. M10 (8.8 grade) 45 Nm (33 ft-lb)
M10 (10.9 grade) 90 Nm (66 ft-lb)
Final drive mounts, replacing
- Remove final drive. See Final drive, removing and install-
ing.
Rear final drive mounts
- Remove rear final drive rubber mounts using BMW special
tools333314,333315,334 181, and334 183.
4 Coat new mount with CircolightB anti-friction agent and in-
.
stall, noting the following:
Long bushing on mount must face forward (arrow).
A shows installation position of mounts.

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Final Drive
Front final drive mount
4 Remove front final drive mount using BMW special tools 33
3312,333314, 333315,334161
and334162.
I i 4 Coat bearing sleeve in rear axle carrier and rubber mount
with
~ircolight~ anti-friction agent.
Slide rubber mount from side with large diameter into
BMW special tool 33
4 165.
Milled recess
(A) makes firm contact with rear axle carrier
when top rubber mount is tightened down.
The
slolled srde ot r11e rubber mounl must be ar r#ghl angles
lo
rhe groove rn specal roo/ 33 '1 165 and shoulo be lrghrened
I down ~ransversely across the vehicle axis. I
Draw rubber mount in firmly with BMW special tools 33 3
314,333315,334164,334165and334166.
NOTE-
Male sure special tool 33 4 166 is properly seated.
0 Rubber mount must locate flush in rear axle carrier. If nec-
essary, rotate special tool
33 4 164 through 90" and draw
in overlap.
- Remainder of installation is reverse of removal

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331-16
I Final Drive
Worlting at top of coil spring, press center cap down or pry
upward to remove. If pushed down, remove from inside coil
spring.
4 Worlting from underneath, position BMW special tool 33 2
301
between 2nd and 3rd spring coil from the bottom.
Make sure tool recess faces upward.
Worlting in cargo compartment, guide BMW special tool
33
2 304
from above and thread into special tool 33 2 301.
4 Worlting in cargo compartment, attach BMW special tools 33
2 302.33
2 303 and 33 2 305 to special tool 33 2 304.
- Use special tool 33 2 306 to compress spring.
Tighten until lower spring end lifts off spring seat on wheel
bearing carrier.
- Model with air springs: Loosen compressed air pipes at air
distribution assembly to release system pressure.
WARNING-
The vehicle will lower when tlie airpipes are loosened.
- Remove final drive. See Final drive, removing and install-
ing.