how to repair U-joint issues in my BMW 3 Series E90/E91 (2005-2012)?

Solution

1. Preparation

• Tools Required: Socket set, torque wrench, universal joint puller, grease gun, and safety gloves.
• Ensure the vehicle is on a level surface, and use jack stands to secure it.
• Disconnect the battery to avoid electrical issues during repair.

2. Remove Driveshaft

• Sub-steps:
  1. Loosen the bolts securing the driveshaft to the rear differential using the socket set.
  2. Remove the rear driveshaft support bearing if applicable.
  3. Carefully slide the driveshaft out from the transmission and the rear differential.

3. Replace U-Joint

• Sub-steps:
  1. Secure the driveshaft in a vise, ensuring it is stable.
  2. Use the universal joint puller to remove the old U-joint by pressing out the caps.
  3. Clean the U-joint cups and ensure no debris is present.
  4. Insert the new U-joint into the driveshaft, ensuring it is oriented correctly.
  5. Press the new U-joint caps into place using the puller, ensuring they are firmly seated.

4. Reinstall Driveshaft

• Sub-steps:
  1. Align the driveshaft with the transmission and rear differential.
  2. Reinstall the support bearing and secure it with bolts.
  3. Tighten the driveshaft bolts to the manufacturer’s specified torque settings.
  4. Reconnect the battery.