Ok thanks! Might have to get a E46 2.93 and take the gearing to a company nearby that make gears and let them look at it :)
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Originally posted by nando View Postit will require more than that. you also have to cut down the ring gear which has to be done precisely.
the pinion is about the same length but the diameter of the bearings is smaller on the E34, and the ring gear is thicker.
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Originally posted by The Dark Side of Will View PostThe E46 ring gear is thicker? What ratios were you looking at?
In all their rear diffs, BMW uses the same carrier across all ratios, and the thickness of the rings gears only varies according to the diameter of the pinion, so I would expect that their front diffs would be made with the same philosophy.
Chris, would you mind refreshing us on which gearsets you've compared?
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E34 on left, E46 on right:
it's hard to tell in the pic but the ring gear is definitely too thick for it to mesh up. you'd have to cut down the backside of it. the bolt pattern is standard BMW 168mm.
looking at it again the bearing on the pinion is the same but the output shaft is bigger. maybe there's enough room to machine the case to fit the E46 pinion and flange, dunno.
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Still waiting for QC guy to get me the data package on the crossmember.
Also, ordered an inner and an outer ball joint from NAPA.
I'll pull a control arm, press the current joints out, measure the control arm carefully for redesign, press the new joints in and reinstall. Then I'll take one of the old joints and cut it apart on the band saw so that I can install the ball in the crossmember for QC guy to give me an exact coordinate for the pivot center of the ball joint and angle of the shank. Those are the only pieces of information that are hard to get about the crossmember.
With that info, I can get cracking designing a new crossmember and control arm setup.
As far as mount arms go, it also occurs to me that E53 mount arms are candidates in addition to E34 mount arms. I could also measure E39 mount arms; while those are less likely to work than E34 or E53, I should cover all the bases.
Code:E34 M50 01 Supporting bracket left 1 11811136537 $31.86 02 Supporting bracket right 1 11811135948 $31.86 E34 M60 01 Supporting bracket left 1 22121702636 $49.83 15 Supporting bracket 1 64551702640 $83.28 E39 M54 01 Engine support, left 1 22111092973 $31.87 02 ENGINE SUPPORT RIGHT 1 22116752648 $31.87 E39 M62 01 CLIMATE COMPRESSOR SUPPORTING BRACKET 1 64551433562 $83.28 07 Engine support, left 1 04/1997 22121745739 $67.38 07 Engine support, left 1 04/1997 22121745739 $67.38 E53 M54 01 Supporting bracket left 1 22111096999 $50.24 02 Supporting bracket right 1 22111097000 $46.00 E53 M62 01 CLIMATE COMPRESSOR SUPPORTING BRACKET 1 64557503477 $83.28 06 Engine support, left 1 22116751345 $137.98
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Thanks!
30mm x 27 spline on a 3.5mm module. The largest module with a 90 degree face angle is 2.5, so those have a smaller face angle, which it looks like on the photos.
The driveshaft spline in the T-case is 35mm x 43 spline on a 2.5mm module, with a 90 degree face angle.
So one of the extended spline fittings could be made that had the front diff pinion splines and threaded shank on the end that normally gets welded into the driveshaft. This would allow the use of the E46 input flange at the T-case front output, which makes it easier to run a fixed yoke with u-jointed driveshaft.Last edited by The Dark Side of Will; 08-10-2014, 04:46 AM.
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Per the above, the pinion splines for a 188mm 4 bolt flange or a 210mm 4 bolt flange could also be cut, but the 168mm splines are probably smaller than those and easier to incorporate into existing design for the extended driveshaft spline fitting.
If the 168mm flange is strong enough at one end of the driveshaft, it's strong enough at the other end.
The only impediment is finding the part number for the E46 front diff input flange. (Either of us could check our flanges for it... you if you can find the flange and me if I take the flange off the diff)
Last edited by The Dark Side of Will; 08-16-2014, 11:08 AM.
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Snagged a used control arm from a junk yard and knocked the ball joint apart today.
The CMM guy my dad works with has measured everything on the crossmember except the location of the ball joint pivot center. I popped the shank out of the ball joint and installed it lightly to the crossmember so that he could locate the center of the sphere and the lateral and longitudinal angles the shank makes with the mounting plane.
The press mandrel to support the control arm needs to have a minimum ID of 1.980. My dad and I used a sleeve with a 2.063 ID which worked fine.
The press mandrel to remove the ball joint needs to have a min ID of 1.400 and a max OD of 1.570... so it's fairly particular.Last edited by The Dark Side of Will; 08-11-2014, 07:54 AM.
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