BMW E21 Differential Refresh BMW 33101208942

[320iAman]

I picked up this Open 3.9 Differential at Pick n Pull for $50. I doing a refresh of the differential, new bearing and seals. I'll post progress as I go along. All seals are in, Bearings are ordered and will be in next week with the BMW Clamp Bush-BMW Crush Sleeve.
DSCI0187.JPGDSCI0188.JPGDSCI0189.JPG


Randy

[320iAman]

Here is the Seal Kit I made up. The piece of candy is free gift from O-ring Store that comes with the O-Rings, those are Viton 75 O-rings.
DSCI0194.JPG

Randy

[320iAman]

Carrier Bearings Removal.

DSCI0195.JPGDSCI0196.JPGDSCI0197.JPG

Instead of using a press, I cut off the cages and removed the bearings, installed the bearing splitter , Then using my Ridgid impact tightened up the screw applying pressure to the race, next I used my bernzomatic torch and heated the race for about 5-10 seconds-360 degrees, one popped coming up and other side stayed put. I then used my impact to remove the races came right out easy.

My side shafts and side shafts bearing holders came out easy with small pressure applied using a medium size pry bar. I used a Spackling tool to start the removal of the carrier bearing holder,, both side shafts have shims and I keep them with the original carrier bearing units and original side shafts.

Heres another thread on this:

https://www.bimmerforums.com/forum/s...ld-(Pic-heavy)

Randy

[320iAman]

Small Hiccup , the large bearing on the pinion shaft order fell out its dealer only item so I source this, 500 in Germany.


Randy

[Retoropak]

Before you put it back together find a lsd pumpkin from the 318i e36 and swap it. I think i payed 65 or 75 for the lsd unit at my local junkyard.
Swap is fairly easy and there is plenty of 318i on the junkyards

[320iAman]

I'll check it out although I'm not a big fan of Lsd's, I did my stint with lsd's many moons ago, I'll take one if its free maybe, as Wild Bill says if its not free its not for me.

Heres some more pictures,side diff. axles, carrier bearings and there shims, flange, pinion gear its big bearing and small bearing , clamp bush and M20 x1.5 Washer/Nut combo. A thin wall 30 mm socket will remove the M20 W/N combo and the securing plate out without having to fish out the securing plate first to remove W/N combo, Yes I have one made it..

DSCI0198.JPGDSCI0199.JPGDSCI0200.JPG

The Clamp Bush or Crush sleeve looks brand new at 2 ft lbs of turning torque, no one crushed this one, lol, its a short nose clamp bush, which when compressed seats the large and small bearings in there races, thats the back story on turning torque,seating bearings and setting bearing load to 22 in lbs ~ 2.49 Joules ~1.83 Ft lbs, more on this later.
The Pinion Shaft came out very easy did not have to press it out or smack hard with plastic, rubber or brass hammer and so forth. If the Pinion shaft will not come out with a light tap this is from the Smaller Pinion bearing being frozen on the shaft, mine slides on and off very easy.

Randy

[320iAman]

The old races are out of the Carrier Bearing units, the shims are identical in size. I put in order at dealership for the Large Pinion Bearing, there's one showing here and 500 in Germany for additional differential refreshes,,

DSCI0201.JPGDSCI0202.JPG

Randy

[320iAman]

DSCI0207.JPGDSCI0203.JPGDSCI0206.JPGDSCI0204.JPGDSCI0205.JPG

My bearing splitter would not reach to remove the large pinion bearing from the pinion shaft, so I called a friend and he pressed it off with a hydraulic press after heating, with out heating it will not want move at all. 3 of 4 Bearings came in, the 4th is ordered thru a BMW dealership as its a dealer only item. The Pinion races were also removed by my friend he put a bead weld around the entire race then put a large nut in each welded them to the race , the smaller pinion race nearly fell out, a slight tap and it dropped from the weight of the drift, the bigger race with the nut welded in fell out with a few taps from the weight of the drift, he told me its important to place a weld bead around the race so that it shrinks from the heat. The Shim in picture 3 is Shim X in the BMW Service Manual and installed first before the big race is installed. Welding the races is much faster to remove races than using a puller or a chisel ect. New Clamp Bush is inbound and the large pinion shaft bearing. Time to think of clean up and the paint service for this BMW Open 3.91 Differential that's being refreshed after installing the Pinion Races Large and Small. Refreshing is same as Servicing.

Randy

[cgifool]

What part numbers do you have for the pinion bearings and races?

Looking at the diagram I'm a little confused.

http://www.realoem.com/bmw/enUS/show...diagId=33_0598

Are parts #7 and #8 (grayed out in this diagram) the "dealer only" parts you ordered?

I have a differential gasket set but mine's leaking fairly steadily from the front seal, and one of the bolts holding it to the rear subframe is completely seized.

Sure would like to fix that oil leak, and potentially replace the bearings, but I'm a little afraid of getting into an ugly situation trying to remove the seized bolt. I would really REALLY like to avoid drilling that sucker out.


Don't remember if it came with the oil seals, o-rings, or securing plate - but I doubt it. Guess I need to make up a shopping list.

[320iAman]

The Big Pinion Bearing Came in Last one in the USA, 500 in Germany, Dealership Order. Got the Beam 80 in lb Torque wrench in with adapters to fit 30 mm Socket, unless you want spend dollars-beam torque wrench is way to go.

Pick n Pull screwed up on drain plug, when they drained the differential they torqued the aluminum plug on so tight it was seized and stripped out on the allen wrench on trying to remove it, so I drilled the plug out progressively from 1/4 to 1/2 Milwaukee hex bits in my Ridgid Gen5x drill driver, I notched the inside of the plug with a Stanley mini hacksaw and then chiseled out a section exposing the threads, I wacked the top collar a few times with the chisel to free it up, I was going to cut another section and it moved, spun right off no damage to threads underneath--careful how deep you cut study it.
DSCI0208.JPGDSCI0209.JPG

The Big Pinion Bearing is in its a Friedrich Fischer-Kugelfischer GmbH(Bosch took over fuel pump from them)-Biggest Bearing Mfg in Germany and part of the Schaeffler GmbH Group, I have now the complete bearing and seal kit,,Clamp Bush will be in tommorrow and available on many vendor sites, CGI the number is in the first picture.

DSCI0211.JPGDSCI0210.JPG

Look here they are not greyed out. I also suggest you put it together like you found it.

http://www.realoem.com/bmw/enUS/show...diagId=33_0598

The thread in Post # 3 has lots of good information and all parts numbers ect by link.

Friedrich Fischer

Friedrich_Fischer_(Schweinfurt).jpg


Randy

[autox320]

fyi; I found all Timken bearings and seals from Rockauto. Think the large pinion bearing had to be punched numbers in manually but they do have it. It's TIMKEN HM88649 is for a 168mm diff.
My SKF set from Pelican were mexican/chinese blend branded. Looks like yours is German?

[320iAman]

Now you know where Kugelfischer comes from. German-Kugelfischer bearings are more expensive. The ones that came out of this differential were all Koyo from Japan. I like HM89446 instead, matches BMW Blueprint Specification for this differential. Make sure dimensions match in any event if varying from a BMW Dealer and the Dealer Sometimes.


Randy

[cgifool]

Hmm. Thanks for the extra info Randy: unfortunately, that bearing says from 9/78, and my car is from 7/78... Looking at diagram for 2002 diffs the inner bearing has a different size, and runs until 1977.

Edit: found it on this one, looks like it matches the 2002 bearing. Inner : 72,2X34,9X25,4

http://www.realoem.com/bmw/enUS/show...diagId=33_0598


Edit: A HA this one shows the old and new bearing sizes in the same diagram -, nothing grayed out

http://www.realoem.com/bmw/enUS/show...98#33121200259

[autox320]

Now you know where Kugelfischer comes from. German-Kugelfischer bearings are more expensive. The ones that came out of this differential were all Koyo from Japan. I like HM89446 instead, matches BMW Blueprint Specification for this differential. Make sure dimensions match in any event if varying from a BMW Dealer and the Dealer Sometimes.


Randy

I looked back at my last order and yeah think I posted the nose bearing. Here's what I bought last 168mm I did.

TIMKEN M86649
TIMKEN HM89446
TIMKEN HM89410
TIMKEN M86610
TIMKEN SET45 (2)
TIMKEN 239146 (2)
sleeves from fcpeuro.com

I've a 30mm impact socket with the edge machined off to fit differentials, and rear transmission flanges. PT in/lb wrench off amazon. PT in/lb wrench off amazon link

Timken is OE on a lot of differentials even in BMW. Last 1991 E30 had apart had Timken in it from factory. That being said the National(chinese) bearings do work a long time if can get the right sizes. My last daily diff had nationals in it. The main brand Advance auto and many parts houses etc sell ya these days.

Nothing wrong with koyo either they actually are another OE found in E36/46 diffs a lot. Main OE honda bearing supplier.

[cgifool]

Here's the shopping list I came up with last night for future reference, including new rubber for the diff mounts. These were for SKF bearings I believe, and for the earlier-size inner bearing.

inner 72,2X34,9X25,4
$34.82
https://www.amazon.com/Differential-...+X+34.9+X+25.4


outer 30,1X64,2X21,4
$24.51
https://www.amazon.com/Bearing-Diffe...+X+64.2+X+21.4


lock plate
23211490120
$2.92 FCP euro
https://www.fcpeuro.com/products/bmw...te-23211490120


pinon shaft seal
33127621206
$8.02
https://www.amazon.com/BMW-Rear-Seal...ds=33127621206


clamping bush (crush sleeve)
33121200259
$2.97
https://www.ecstuning.com/b-genuine-...v/33121200259/


side bearing x 2
41,2X73,4X19,5
33131213892
$20.18 (apiece)
https://www.amazon.com/Carrier-Beari...ds=33131213892






o-ring D=81MM/2MM x 2
33113604119
$3.57 (apiece) fcp euro
https://www.fcpeuro.com/products/bmw...mm-33113604119




shaft seal x 2
33121205302
$26.65 apipece
https://www.ecstuning.com/b-genuine-...h/33121205302/

corteco version of the shaft seal
$10 apiece
54 X 38 X 10 mm
https://www.amazon.com/CORTECO-CFW-S...ds=33121205302


rubber diff mounting x 2
33171117282
$29.54 apiece
https://www.turnermotorsport.com/p-5...uine-bmw-part/

[320iAman]

Interesting about differences in these differentials and Timken info, be a delay in large bearing, I inspected it more closely and found out that it had discoloration on several of the rollers resembling rust, so the BMW Dealership took it back and ordered another from Germany no extra charge, so it will be about 7-10 business days. We are the final quality control. ,,New ones should be shiny on the entire roller bearing 360 degrees ect.

While were playing with show and tell..

Bearings
SKF BR35 x 2 -Bearing Cover Bearings
SKF M86649/610-Small Pinion Bearing/Bearing Race
BMW 33121206739-Large Pinion Bearing/Race

Seals
Corteco 01025572B x 2 -Bearing Cover-Drive Flange Seals
BMW 33127621206 -Pinion Shaft Seal
O-Ring Store 2mm x 81mm Viton 75 x 2-Bearing Cover-O-Ring Seals
BMW 33113604117- Differential Gasket

Lock Plate
BMW 23211490120

Clamp Bush- Crush Sleeve
BMW 33121200259

Permatex High Tack , Permatex 2, Possible Curil T around the Bearing Cover-Drive Flange and Pinion Seals
Super Lube on the Viton 75 O-Rings
Permatex High Tack or Curil T on Differential Gasket
Permatex High Tack ,Locktite Blue 242, or Red 271 on Bearing and Differential Covers Bolts

Differential Ring and Pinion Gear Tooth Pattern-Gleason Teeth not Klingelnberg Teeth

Randy

[autox320]

Randy, I vote this thread should be "Parked" for reference.

If anyone has done a transmission or knows a link to piece by piece I've never done one.

[amarino]

If anyone has done a transmission or knows a link to piece by piece I've never done one.

Like this? http://www.bmw2002.net/pdf/Getrag245.pdf

[autox320]

Like this? http://www.bmw2002.net/pdf/Getrag245.pdf

amarino thanks man. I also just googled and found it in your older post post 32 from amarino E21 Factory service manual PDF

transmission starts about page 245 out of 705! Great manual I've a S14 grpA pdf but the pics aren't as good as this (broken black and white; some fragmented)

[320iAman]

Painted the Differential Cover, Bearing Covers, and Differential Housing

The Differential Cover was sprayed with Lacquer Silver Metallic Paint and I seen the tiny aluminum flakes in the air when spraying-the Metallic part of the paint. The Covers and Housing Lacquer Gloss Black. A few shots of the Differential Housing.

DSCI0213.JPGDSCI0214.JPGDSCI0215.JPGDSCI0216.JPG

Randy

[320iAman]

autox320

Randy, I vote this thread should be "Parked" for reference.

If anyone has done a transmission or knows a link to piece by piece I've never done one.

----

Theres one in there now in FAQ's by Mr Gumby-link I cited in Post #3 , it could be linked to that one for extra reference and so forth.

As too the Transmission--Generally its a bearing,seal and Brass Syncromesh Ring replacement--this is what Transmission shops do, the way you learn is take one a part and put it back together, also take pictures of it detailed.

Randy

[amarino]

amarino thanks man. I also just googled and found it in your older post post 32 from amarino E21 Factory service manual PDF

transmission starts about page 245 out of 705! Great manual I've a S14 grpA pdf but the pics aren't as good as this (broken black and white; some fragmented)

Yeah I've been hoarding things for as long as I can remember. Some sites just don't get renewed / lost like 77e21.info . Then the whole Photobucket fiasco really lost a lot of good content.

You got the S14 stuff why don't you share it? :P The more people that have it the better!

[320iAman]

80 in lbs Torque Wrench I got in to set turning torque or bearing load when I'm at that stage of the refresh or servicing. I also bought 1/4" to 3/8" adapter and 3/8" to 1/2" adapter for my 30 mm deep socket, like autox I ground it down to make it thin wall--I made two of these, some time ago.

s-l1600.jpgs-l160n0.jpgs-l500.jpgs-l1600n.jpg


Randy

[320iAman]

I scratched the race when measuring the install depth,oops. I welded a bead around the race and it tapped out with a screwdriver and a drift. I have another bearing race ordered SKF M86610. I have a welding machine I modified with more expensive features-Added Edwards 599 Transformer to power the flux wire feed motor, this way the motor does not tap the Voltage of the welding circuit, this feature is found in more expensive welders, like many more dollars, the mod was ~$20 plus with dual spade connectors and so forth, In case your into this the Edwards Transformer is a step down transformer taking 120V AC and stepping down to 24V AC with 40 VA ~ 40W power , Edwards 599 is dedicated.
DSCI0217.JPG

The BMW Clamp Bush / Crush Sleeve came in a few comparisons photos of New and Old.

DSCI0218.JPGDSCI0219.JPGDSCI0220.JPG

Installed the Bearing Races in the Bearing Covers, ordered Permatex High Tack and ordered a replacement Aluminum Plug-Original 10 mm Hex Overseas BMW Dealership and have a Steel Plug coming in that matches quite well the aluminum plugs fill & drain on the Differential Case and Cover, M22 x 1.5mm.

Randy

[320iAman]

Installed the New SKF M86610 Bearing Race in the nose of the differential. Found and bought SKF Made in Germany Large Pinion Bearing and its Race for $30.87 inc shipping, I have two Differentials.
s-l1600.jpg$(KGrHqRHJEMFIrJYdJ41BSPZCtL98w~~_32.JPG

Randy