Repairing the gearbox output flange on a BMW 518i E28 involves several steps and requires a good understanding of automotive mechanics, as well as the appropriate tools and safety precautions. Find all the information you need in the download manual……
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Below is a detailed guide on how to perform this repair, including the necessary components and tools.
### Components Involved:
1. **Gearbox Output Flange**: This is the component that connects the gearbox to the driveshaft. It is crucial for transmitting power from the gearbox to the wheels.
2. **Driveshaft**: The component that transfers power from the output flange to the rear differential.
3. **Flange Seal**: A rubber or composite seal that prevents transmission fluid from leaking out of the gearbox.
4. **Bolts and Washers**: These are used to secure the output flange to the gearbox. Ensure you have the correct size and type.
5. **Transmission Fluid**: This is needed if fluid has leaked out during the repair.
6. **Tools**:
– Socket set (metric)
– Torque wrench
– Pliers
– Screwdriver set
– seal puller (if necessary)
– Hammer (for any tapping required)
– Rags for cleaning
– Drain pan (to catch any leaking fluids)
### Safety Precautions:
1. **Ensure the vehicle is on a flat surface** and use wheel chocks to prevent rolling.
2. **Wear safety goggles and gloves** to protect your eyes and hands.
3. **Disconnect the battery** to prevent any electrical issues while working on the vehicle.
### Step-by-Step Repair Process:
#### 1. Lift the Vehicle
– **Jack up the vehicle** using a hydraulic jack and secure it on jack stands. Make sure it’s stable before proceeding.
#### 2. Remove the Driveshaft
– **Locate the driveshaft**: Follow it from the rear differential to the gearbox.
– **Unbolt the driveshaft**: Remove the bolts connecting the driveshaft to the output flange. You may need to hold the driveshaft with a wrench to prevent it from spinning.
– **Disconnect the driveshaft**: Carefully slide it out from the output flange. Be mindful of any remaining fluid.
#### 3. Remove the Gearbox Output Flange
– **Inspect the flange for bolts**: Identify the bolts holding the output flange to the gearbox.
– **Remove the bolts**: Using the appropriate socket, unscrew and remove the bolts.
– **Pull off the flange**: If the flange is stuck, gently tap it with a hammer or use a puller if necessary. Be careful not to damage the surrounding parts.
#### 4. Inspect and replace the Flange Seal
– **Remove the old seal**: Use a seal puller or a flat screwdriver to carefully pry out the old seal from the gearbox. Be cautious not to scratch the surface.
– **Clean the area**: Wipe down the sealing surface in the gearbox with a clean rag to remove any debris or old sealant.
– **Install the new seal**: Lubricate the new seal’s edge with a bit of transmission fluid and press it into place. Ensure it sits evenly and flush with the gearbox surface.
#### 5. Install the New Output Flange
– **Position the new flange**: Align the new output flange with the mounting holes on the gearbox.
– **Secure the flange**: Insert
and tighten the bolts to the manufacturer’s specified torque settings using a torque wrench. Consult the service manual for the exact torque specification.
#### 6. Reattach the Driveshaft
– **Reconnect the driveshaft**: Slide it back onto the output flange and align the bolt holes.
– **Bolt it down**: Secure it with the bolts you removed earlier. Again, use a torque wrench to ensure proper tightness.
#### 7. Refill Transmission Fluid
– **Check fluid level**: If necessary, add transmission fluid to the gearbox through the fill hole. Make sure to use the correct type of fluid for your BMW.
– **Inspect for leaks**: After adding the fluid, inspect the area around the output flange for any leaks before reassembling everything.
#### 8. Lower the Vehicle
– Once everything is reassembled, carefully lower the vehicle back to the ground.
#### 9. Test Drive
– **Take the vehicle for a short test drive**: Check for any unusual noises or vibrations, and ensure the gearbox is functioning correctly.
### Conclusion
Repairing the gearbox output flange on a BMW 518i E28 requires patience and precision. Make sure to follow each step carefully, and always refer to the vehicle’s service manual for specific details and torque specifications. If you’re uncertain or uncomfortable with any part of the process, consider consulting a professional mechanic.
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