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E46 Xi Forum
The E46 XI was produced from 01-05 in sedan and touring body styles. Powered by either a 2.5L inline 6 in the 325xi or a 3.0L inline 6 330xi. Discuss all thing about BMW AWD E46 'Xi' here.

 
 
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Old 05-11-2019, 10:07 PM   #1
KyleJ333
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Join Date: Apr 2019
Posts: 2
2004 E46 325xi Axle replacement gone bad

Hi Everyone,

Brand new BMW owner here (like less than 30 days) and I ran into an issue with replacing the passenger side front axle on my 2004 325xi.

I removed the old axle without any issues. it was a little hard to pop out, but it came out just like the several axles on vehicles i have changed out in the past.

My issue starts when I went to slide the new axle in. It slid in and I used a rubber mallet to help it is the rest of the way. About 2 inches from sitting flush with the front differential, that axle stopped moving in. I used more and more force on the rubber mallet, but it wont go in further. Since i knew this should not be normal I stopped trying to force it in the rest of the way.

I then went to remove the axle and it is stuck, like I mean not coming out. I used a 16 in solid iron coal chisel and smacked it a bunch of times with a 5 lb lump hammer and it is not moving. The edges of where the axle sits flush with the differential are totally chipped up from the amount of force I am using to hit this axle out of the differential. In my experience the axle should have come out a long time ago and not require this much force.

I even put a chain around the axle and used a slide hammer on it and it will not come out.

I read later in the forums that the C-clip used one non-OEM axles is too big and prevents the axle going it and being removed. Is this true? The axle was bought from Oreilly's Auto parts, and is a Master Pro CV Axle shaft, part number MP9282.

Sop after all that I am asking if anyone has any advice on how to proceed further? I am considering removing the other front axle and then pulling the front differential and seeing if i can remove the axle one the diff is out of the car.

Does anyone have any advice on what to do or how to take the front diff apart to get the darm axle out of the diff?

Thanks for reading and all the help. From what i saw reading the forums, this sounds like the best place to go to for good advice.

Cheers,
Chris
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