Tech/service manual infomation needed badly. (order of assembly)

[JimmyMac]

07 620i (early vin)

I rebuilt the front differential, now I cant get it to engage. There is battery voltage at the connector but the hubs wont lock. I think I assembled it incorrectly.

There are some components that I am not positive about where they go.

Two shims.
One star/tang drive lock??


2623



Does one shim go against the small outer housing....then the star piece...then the snap ring? Other shim against the other large housing? Like this???

2624

Everything was laid out on the floor...I am on crutches and have to work on the floor right now, this is really why I don't have it right...one of my helpers...(see big white dog) rearranged those parts for my convince. Now I need some help finding the order of assembly.

Can someone please take a gander at their tech/service manual??

Thanks

JMac

[JimmyMac]

*UPDATE*

Found the order of assembly.

After the bearings hubs and seals are installed...

Start with the small side of the case halves. It has the wires and connector.

2626

See the brown guy? I put some moly on him to hold him in place...

2627
This guy first. Tabs sticking up. Later they will need to slip in the bearing cage...so pay close attention to them.

2628
Likea Deis!

[JimmyMac]

Next is the Shimmmm!

2629
I put the curve up, like a cereal bowl...

2630
Lika Deisa Here!

[JimmyMac]

And then the snap ring...

2631
Badda Bing

2632
Badda Boom

2633
Forgetaboutit....

[JimmyMac]

That was what I had assembled wrong the first time... I had the shim first then the star/tab thing.... It's midnight. I haven't tested it yet, so I could have a bad something else, but there is no more time for this week.... we roll out in the am for a weekend at mudmuckers.... either it will wrok, or I'll be driving around the fun stuff. Either way we're there!

To finish it up....

2634
Ring gear and rollers and their cage...(the tangs from the star thing fit into here. be careful to get them in the cage.)

2635
Theres is the other shim...it goes on this side of the ring gear.

2636
Ta Daaa! (hope it works!!)

Will send some pictures from the weekend.

Happy Gatoring!

[Dane]

Thanks for documenting it. I'm sure someone in the future will find it very helpful.

[JimmyMac]

UPDATE 9/3

Works perfectly!!