Differential clunk fix

[Liamd]

Hi,
I'm trying to fix the infamous differential clunk on my 2003 E85, however I can't seem to find the right size socket to get the drive input flange off. I read on one of the guides on here that is is a 30mm, however it seems to big and doesn't fit in between the nut and flange, I have tried using 3/8 and 1/2 inch square drive as well as impact and non impact, (yes, for some reason I collect 30mm sockets) I have tried 29mm, that fit in between the nut and flange but not over the nut, perhaps I need to try imperial size?
Can anyone help with this?
Also does anyone know what torque it has to be tightened up to when I eventually get it off? I can't find it on TIS.

Cheers.

 

[smorris_12]

Assuming the size is 30mm it looks like it wants a really thin wall socket.

Alternatively, a good dodge I've used for big nuts before now is to use hammer and cold chisel on one of the flats and tap it round to undo it. Might be hard work with the outer flange there tho.

 

[Rockhopper]

Be careful not to damage it, the flange and nut are not available new as they need to stay with the dif they were originally fitted to.

 

[patriot66]

Hi Liamd. So it looks in your photo like you've un-staked the security washer. I bought a 30mm socket as I didn't have one and ended up reducing the wall thickness with an angle grinder until it would just fit snugly.
You don't torque the flange nut. You need to mark the nut in line with the centre with either a scriber or white paint etc. Carefully loosen the nut and count how many full turns before it comes off the threads. It looks like maybe someone has scribed '2 X' on it in your photo. However, IIRC mine was 7 turns approx, so 2 turns doesn't seem very much. Just carefully count how many turns as you remove it and you'll be fine. Also make sure you 'stake' the new washer into the two indents

 

[Liamd]

Thanks for the advice. I didn't know you can get thin walled sockets, I've had a look on eBay and bought one, if that doesn't fit then I'll get the grinder out.
Patriot66, you've highlighted a few steps I was aware of, so thanks for that insight. Socket arrives Saturday so I think I'll have a bash on Sunday.
Again, many thanks for the advice

 

[patriot66]

Thanks for the advice. I didn't know you can get thin walled sockets, I've had a look on eBay and bought one, if that doesn't fit then I'll get the grinder out.
Patriot66, you've highlighted a few steps I was aware of, so thanks for that insight. Socket arrives Saturday so I think I'll have a bash on Sunday.
Again, many thanks for the advice

Keep us posted

 

[coldel]

Good timing with this. Been fixing a number of niggles on my car, happy with the progress so far! One thing that bothers me though is the very quiet clunk from the back of the car when putting it under load and also letting off load. Mostly at slow speeds. Is this the clunk you are trying to fix here?

In short, what work is needed to be done? Is there a guide on here already?

Or should I be taking it down to say RBM or local specialist to do this?

 

[inkey$]

Good timing with this. Been fixing a number of niggles on my car, happy with the progress so far! One thing that bothers me though is the very quiet clunk from the back of the car when putting it under load and also letting off load. Mostly at slow speeds. Is this the clunk you are trying to fix here?

In short, what work is needed to be done? Is there a guide on here already?

Or should I be taking it down to say RBM or local specialist to do this?

Reading up on the forum, I think sometimes it can sometimes be as simple as the diff needing to be greased up so its not dry.
https://z4-forum.com/forum/viewtopic.php?t=127598

 

[coldel]

Thanks Inkey the link through that link shows the work, i.e. exhaust off, propshaft out, etc.

Not something I can do, looks a nightmare if up on axle stands!

 

[Liamd]

Coldel, yes that's what I'm trying to fix. I've not a fair bit of research and to fix it all you have to do is take the diff input flange off and put some grease behind it. The grease acts kind of like a shock absorber I believe.

 

[coldel]

Thanks Liam, yes the clunk doesn't do anything but given my misophonia it does drive me crazy!

 

[patriot66]

Good timing with this. Been fixing a number of niggles on my car, happy with the progress so far! One thing that bothers me though is the very quiet clunk from the back of the car when putting it under load and also letting off load. Mostly at slow speeds. Is this the clunk you are trying to fix here?

In short, what work is needed to be done? Is there a guide on here already?

Or should I be taking it down to say RBM or local specialist to do this?

This is what is entailed, more or less
https://z4-forum.com/forum/viewtopic.php?t=55471&sid=d7cbdadcfc327e7db2d30c534548e474

 

[coldel]

Great share thanks. Looks like something to go into a garage to do I think. Would be a bit of a mare doing that lying on your back

 

[patriot66]

Great share thanks. Looks like something to go into a garage to do I think. Would be a bit of a mare doing that lying on your back

It's not too bad tbh. I've done worse jobs with less room

 

[M@_]

I’m assuming it’s not the bushings for you then?!? I recently changed my diff bushes and it solved my clunk. No need to remove the big nut if it’s bushings.

 

[Liamd]

I have recently changed all bushings to poly ones, but I thought I'd do this anyway as a preventative fix.
I bought a thin walled 30mm socket off ebay, however turned out to be a standard socket, couldn't be bothered sending it back so got the angle grinder out and had some fun
I marked a straight line with a paint pen across the nut and flange, put the socket on and marked a line on the socket to match up with the flange.
The nut was an absolute pig to crack off, really tested my new handbrake shoes. Once cracked off, it came off with ease. Anyway, took 8 full turns to come off, the flange came off quite easily, no need for any tools, got her lubed up and slid it back on (insert witty innuendo).
Put the nut back on and locking washer. Obviously making sure all marking line up. Job only took about 15 mins.

 

[patriot66]

Nice one Liam ....but has it stopped the 'clunk' ?

 

[Liamd]

Won't know for another couple of weeks yet, I'm busy with work this week, so I don't have time to put everything else back on the car. Bloody work getting in the way as usual.

 

[patriot66]

:roll:

 

[Liamd]

Just went for a little drive today and the clunk has gone. Success.