Output shaft broken / upgrade - how easy?

[Kreindler]

Finally, 9 month later i got my car painted.
Now, I bought a dragy, and went to play a little and try some 0-60 times.
Unfortunately on second try - my left output shaft said "poc" and broke done

Now i was thinking of using the opportunity to upgrade them.

My output shafts are the stock 520i ones (PN 33201229371 LK=80MM/D=32MM)

On other models (520d, 525tds and 530i), the output shafts are thicker (PN 33201229449 LK=86MM/D=38MM)

Now i was thinking / if I change the parts circled in the screenshot from my diff - would the thicker output shafts be a plug and play swap?shaft mount.JPG

[JimLev]

Did the output flange or the output shaft break? Seems that a 520 wouldn't have enough power to break either.
The output flange is only held in with a clip, if it popped out check the clip.
If you change the output flange (#15) you'll also need to change the output shaft (1/2 shaft)

[Kreindler]

Did the output flange or the output shaft break? Seems that a 520 wouldn't have enough power to break either.
The output flange is only held in with a clip, if it popped out check the clip.
If you change the output flange (#15) you'll also need to change the output shaft (1/2 shaft)

Check signature It's actually a 530i with a 3.46 diff (from the initial 520i).

I marked on this picture where it is brokenCapture.JPG

[ross1]

That's the CV joint. If original to your car's 2.0 configuration it could be a light duty version.
Plug in your VIN at that parts site and see what other cars that output shaft fits. If only tiny engine versions you may want to upgrade or quit thrashing the car.

[Kreindler]

Oki, so i clearly have to upgrade it, there is no doubt in that (long term plans are 300hp n/a tune)

The question is: can i keep my current diff and just install the parts circled here from another e39 (530d)?


Cause if so, i would put the CV joint and output shaft of the 530d. That is way thicker then this one, so that it can support abuse


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[Kreindler]

I found out the 530d has a big case diff (210mm), so most likely things differ there a bit.

My interest is if the so called “Drive flange output” (number 15 on the diff schematic from realoem) from another diff with stronger CV joints and output shaft can fit my 520i 188mm diff.

Fortunately i have an e53 diff (also from a 3.0d model) lying around, which i purchased in order to swap the internals into mine (has a 3.73 ratio and the case is also a 188mm, so hopefully internals should fit my diff).
I saw on realoem the 188mm diff from the e53 comes with either a 86mm or a 89mm diameter “Drive flange output”. I will measure mine, and if it is 86mm- i will try to see if the drive flange can be fitted plug and play to my diff.

If all my above assumptions are correct, i could have as an end-result a diff with a ratio of 3.46 (now) or 3.73 (if internals from e53 diff fit) and the more solid cv joint and output shaft of the 530i (530i’s stock are using 86mm drive flange outputs according to realoem).

I will update this thread with the progress.

As for now- i can’t wait for the next run with the dragy. I am enthusiastic because my first ever tryout, even if far from perfect (28 degrees fahrenheit outside, summer tires, imperfect start, and a 2% incline) rendered what i consider a decent time



Corrected time (without the incline) would have been 6.6


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