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      03-23-2012, 04:55 PM   #111
e92zero
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^infantrytroop22, as answered already, removing the exhaust hangers have no effect. However, I can imagine if someone go crazy tightening the 2 nuts on the exhaust hanger or if the threads on the nuts are not smooth, they can run the risk of loosening the bolts because the direction on tightening the exhaust hanger nuts is the same direction as loosening the bolts. So what I would do if I remove the hanger nuts is to make a mark on the bolt side and make sure they didn't move after you put the exhaust hangers back on. Can never be too careful, right?

^chriszeh, not sure if that was a joke or not, but I have to remove the exhaust and the heat shield to get a torque wrench in there. I am not sure how othe folks get a torque wrench in there to check that they are at the right torque. There aren't much space in there to put a torque wrench to check 100 NM.
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      03-23-2012, 08:11 PM   #112
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Its the main body of the differential housing that is in the way for me.
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      03-26-2012, 12:32 PM   #113
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I was cross referencing some of the bolts in the various bmw subframe and suspension area and here are some finding.

The differential housing bolts on our m3 is m12 x 1.5 x 100 full threaded, grade 10.9 part number 33176760343.

For the new F10 M5, the differential housing uses a m12 x 1.5 x 110 grade 10.9 bolt. It's not fully threaded in the diagram. Part number 07119906460.

Our M3 rear subframe bolt also is not a fully threaded bolt (based on the diagram) at m12 x ? x 110, grade 10.9. I can't confirm the thread pitch of this bolt though. Part number 33306793892.

Any one confirm that maybe we can use these bolts that are not fully thread instead? They are about 10 mm longer but that shouldn't be an issue. When I get a chance, I will swing by the dealership to confirm but if others already can get a hold of these bolts, maybe they can charm in.

Last edited by e92zero; 03-28-2012 at 02:52 AM.
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      05-19-2012, 04:19 PM   #114
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+1 differential bolt failure. has anyone tried changing the diff mounts to solid bushings?
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      05-20-2012, 02:01 PM   #115
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yes they are available from turner i believe.
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      05-21-2012, 01:12 AM   #116
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My car has the same problem (2011 E92 @ 18200 miles) and the dealer told me that rear subframe will be replaced. They will call me about it tomorrow. I was completely positive that it would be covered under warranty but now that I read this thread I'm really anxious.
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      05-21-2012, 05:43 PM   #117
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Quote:
Originally Posted by centauri View Post
My car has the same problem (2011 E92 @ 18200 miles) and the dealer told me that rear subframe will be replaced. They will call me about it tomorrow. I was completely positive that it would be covered under warranty but now that I read this thread I'm really anxious.
Make sure that they agree to cover it before authorizing any work to be completed (I'd make that clear ASAP if you haven't already). You'll be in a much better position to negotiate before the work is completed in the event that they don't want to cover it.
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      05-27-2012, 03:55 PM   #118
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maybe someone should start a recall process on the diff bushings? too many failures in my opinion...
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      05-27-2012, 06:29 PM   #119
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I dont have a m3 but i replaced mine with the turner and there is no vibration or noise.
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      05-28-2012, 03:21 AM   #120
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how long is the install process for the differential mounts? does the exhaust have to be removed?
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      05-28-2012, 03:25 AM   #121
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Quote:
Originally Posted by e92newb View Post
how long is the install process for the differential mounts? does the exhaust have to be removed?
Yes,,and the rear subframe has to be dropped..and you need a bushing press..not a DIY unless you have the right tools
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      05-28-2012, 06:42 AM   #122
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Quote:
Originally Posted by tres View Post
I dont have a m3 but i replaced mine with the turner and there is no vibration or noise.
Nice! Did you do this yourself or a shop/dealer? How long did it take you or the shop/dealer in question? Thanks for the pics and info!
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      05-28-2012, 12:15 PM   #123
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i did it on my 2007 and it took me 3hrs total, getting the bushings out is easy. Pressing them in takes a little patience. I used a balljoint press and a bushing driver and hammer. The second time i had a friend do it.




Quote:
Originally Posted by Singletrack View Post
Nice! Did you do this yourself or a shop/dealer? How long did it take you or the shop/dealer in question? Thanks for the pics and info!
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      05-28-2012, 12:18 PM   #124
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It should take 3 -4 hrs. and the exhaust has to be removed makes it alot easier. The subframe doesnt have to lowered or removed.



Quote:
Originally Posted by e92newb View Post
how long is the install process for the differential mounts? does the exhaust have to be removed?
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      07-16-2012, 11:26 PM   #125
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Just a small rant: I suffered from this same issue of broken bolts but it caused a little more damage. I drop my car off at the dealer over the weekend and came today (monday) to talk with the service advisor. Its seems the damage according to BMW is faily large, $10,000 large, diff, subframe, exhaust shields, bolts, and driveshaft. The dealer basically told me that the car is not meant to be beaten and that they will pull the log, and that it may or may not be covered by warranty. Now I'm pretty scared that this is not going to be covered as there was little to no assurance of what will be happening. The funniest part about this is a few weeks ago I heard a loud thud from the diff and decided the bring the car in for a check-up as the subframe was also rusted. The dealership told me that everything was normal and even rust was normal, they just put some paint to clean it up. Its a BMW certified 2008 m3 6speed with 20k miles, never winter driven and from the looks babied by previous owner.

I have had some track time on the car of maybe about 20-30mintes and I wasn't really beating the car. I've launched it a few times but never above 3500rpm, and I figure a DCT you can launch at 4000-6000rpm, then 3500rpm I'm in the safe zone. The dealer said they never seen this before which I do believe but it seems fairly common on these boards.
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      07-17-2012, 09:04 AM   #126
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Weird I have had the same problem with my M3, i was launching it off of a red light and then all of a sudden that popping noise comes and then it doesnt move when i have it in gear anymore (6MT) so i took it to BMW they basically told me to screw off in different words because they did not want to eat the job, so now I have not driven my car in about 2 months and currently waiting on parts from BMW which are back order just my luck. Im surprised to see people having the same problem, I had to replace one axle shaft, diff housing and the rear muffler.
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      07-17-2012, 02:05 PM   #127
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Quote:
Originally Posted by e92livin View Post
Weird I have had the same problem with my M3, i was launching it off of a red light and then all of a sudden that popping noise comes and then it doesnt move when i have it in gear anymore (6MT) so i took it to BMW they basically told me to screw off in different words because they did not want to eat the job, so now I have not driven my car in about 2 months and currently waiting on parts from BMW which are back order just my luck. Im surprised to see people having the same problem, I had to replace one axle shaft, diff housing and the rear muffler.
Wow, we should honestly make a class action suite against BMW. These bolts should not fail, I never heard of another car doing this minus e36 m3s. I've heard of many ppl breaking axles on other cars never diff bolts. A $500 axle vs $10,000 diff cause of bolts is just mind boggling.
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      11-17-2012, 04:23 PM   #128
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Quote:
Originally Posted by Richbot View Post
I was just looking into that. I can't find 12.9 bolts in M12x100 body fit (partial thread) anywhere.

...

Well, a 12.9 socket head cap screw seems like the best bet, that new zealand site isn't very informative and he's probably selling SHCS's. Yield stress is 60MPa higher on than the minimum tensile stress of the 10.9 bolt but not sure how brittle they are. I would really want to know more abuot the failure mode before I changed anything.
Any update on this? I am searching for a 12.9 bolt with the correct dimensions but so far all the suppliers I tried can't find one.
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      11-21-2012, 03:36 AM   #129
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just curious how many miles are on the vehicles in question...? i read this entire thread. not everyone with failures listed mileage, but for those that did, i cant recall anyone having much more than 20k on the odometer. Just speculating, but could that mean some cars may have faulty bolts from the factory while others may not? or are folks thinking this is just bad design and engineering? Im nervous as I just signed the papers to buy an 08 e92 with 39,500 on the odometer - and the warranty is already expired...!

also curious if anyone has paid a local shop to install the solid mounts listed earlier and what that might cost for labor? from the pics, it didnt look too bad of a job *if* you had the right tools. $179 for the part + labor is likely worth the piece of mind...!
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      11-21-2012, 12:23 PM   #130
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Quote:
Originally Posted by tl351698 View Post
also curious if anyone has paid a local shop to install the solid mounts listed earlier and what that might cost for labor? from the pics, it didnt look too bad of a job *if* you had the right tools. $179 for the part + labor is likely worth the piece of mind...!
See my thread and sig. Labor depends on many factors but expect it to be anywhere from 1-2 hours.
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      11-22-2012, 08:49 AM   #131
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Dang reading threads like this one scares the crap out of me! I really hope BMW would do a recall and put in a beefier bolt.

Malek, you recommend the solid aluminum differential bushing? If so, I may need to swing by and have it installed!
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      12-03-2012, 09:38 PM   #132
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I am affected by this and joined this forum as a result of reading this thread.

I have a 2011 (100% stock, never modified) with 25k miles on it. I currently own three M3s -- two E46s and this E92. The E92 is my 'happy' car, I love the near-telepathic throttle response and drive it after particularly long days to unwind. The car (unlike my E46s) has never seen the track, has never been abused, and has never even had a bent 19" rim.

I took the car to the dealer (where I purchased the car) after hearing a faint clunking noise from the rear. A week later I am handed a "quote" for $6000. The differential bolt is broken off at the bushing. The dealer claims the sub-frame must be replaced. The dealer had an "FSE" come look at the car, who claims the car has had bottom impact damage.

I asked to see the damage myself and the damage is an inch long maybe 1/8" deep scratch to the passenger side fuel tank and some wear on a few of the differential fins, maybe from kissing a speed bump or road debris?

The dealer wants to replace the subframe, differential bushing & bolts, and fuel tank. They claim due to the "impact" it is not a warranty issue and I have to go through insurance.

I have a perfect driving record; going through insurance will be an at-fault accident which is unacceptable to me. I did not hit anything with the car and I have a hard time believing the fuel tank damage (a scratch, basically) is correlated to the differential, especially since the fuel tank sits higher than the exhaust and there is no exhaust damage whatsoever.

Dealership technician confirmed they found no hints of abuse whatsoever and could tell I took really good care of the car, saying it was "perfect" -- but claim they have never seen a broken differential bolt before and it must have been caused by impact. They also claim that it is BMW's decision and not theirs since the FSE wrote it up as accident damage.

Not sure how to proceed, advice appreciated. I think I could have the car towed to a reputable independent and have a new bushing and bolt installed at minimal cost, since this appears from this thread to be a relatively common issue, but I feel cheated by the dealer and their response.

Last edited by bvanderbilt; 12-03-2012 at 09:45 PM.
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