Front Prop shaft & Transfer box.. Big bang theory!

[Steamyrotter]

Well having significantly tempting fate in another thread...

Greeted with very loud bang under car when pulling away from traffic lights and lost all drive..
Nice grating whirry noise and no go!

Car evenetually recovered under cover and strip down has shown that the splines on the front prop shaft and those in the socket on the transfer box have had a serious disagreement and decided to go their separate ways!!

To say the least i was not overly happy but then remembered i have a spare shaft and transfer box at home..
Only to find the transfer box is a completely different design than mine and therefore will not fit.. >:(
Many thanks BMW Design department...!!!

Will need to talk to a machining mate of mine to modify the spare output shaft to hopefully get it to fit!!
(unless anyone has a spare they want shot of??)

PITA.. It just passed MOT, but luckily hadn't renewed Tax yet, so will be SORNing it again!!
:'( :'(

on the plus side at least it did it then and not the following day when i would have been towing a horse in a trailer.. That would have been interesting with Green Flag!!!

[shadrack]

i think i'd be getting rid if i was you!

[Steamyrotter]

lol

Don't you start!!

Well got the bearing sorted on the spare transfer box output shaft and all back together OK.

I have added spacers tot eh front of the shaft to ensure maximum engagement of the splines into the socket (managed to get a further 3/4 inch engagement).  I cut the flange off of the end of thw old prop shaft, ground down the high spots and used that as the space at the front diff doughnut!

Only to find, obviously, the bolts were now too short..
Ever tried to find Grade 10.9 bolts at 75mm long!!!  Not easy.  Settled for grade 12.9 and cap head.  Stronger and a bit easier to get a ratchet on there with a decent 8mm allen key head on it!!

Now driving it very lightly and listening for every noise!!