Propshaft Failure

[seanegee]

I'm reading stories of a notorious issue for the F15, regarding the prop U joint failure, due to an ill-placed AC component leaking above? Is this as well known and is there a preventative measure recommended?

[SunjaKim]

Originally Posted by seanegee

I'm reading stories of a notorious issue for the F15, regarding the prop U joint failure, due to an ill-placed AC component leaking above? Is this as well known and is there a preventative measure recommended?

https://f15.bimmerpost.com/forums/sh...2012697&page=3

[SunjaKim]

The AC condensate drain is above the TC, but the failures are more likely related the salted roads, ultra cheap original U-joints, and insufficient spline engagement in the TC.

[tlow98]

Originally Posted by SunjaKim

The AC condensate drain is above the TC, but the failures are more likely related the salted roads, ultra cheap original U-joints, and insufficient spline engagement in the TC.

Agree. The slop in tolerance stack would have this situation unraveling quickly once the u-joints start to go.

[Tomcat_F15_STL]

A visual inspection of the front u-joint will tell you if you have a defective propshaft. I doubt if the condensate drain has anything to do with the failure.

If it is covered in a dusting of dry rust you need to replace it ASAP.

[Clifton]

I recently performed a transmission service (pan & oil) and used the opportunity to inspect the underside without body panels. I noted slop in the front driveshaft as well as light grease splatter pattern coating the areas around where the U-Joint spins.

I suspect that some of the slop in the shaft is causing uneven torque combined with centrifugal force resulting in the grease to slinging out from the joint. Once that joint dries out, the metal on metal will accelerate the wear and lead to destruction. That's my hypothesis anyways...

My U-joints did not have rust, but I imagine if you live in a harsh climate, the rust will contribute to an even faster demise.

To Tomcat_F15_STL's point, the condensation drips on the front U-joint, but the failure seems to happen at the rear where the U-Joint enters X-fer case.

In my case both front/rear U-joints did not have rust, but the rear joint had the grease splatter.

[LateParty2018X535d]

I was at the Euro Mechanic today for unrelated issue and inspection turned up this propeller shaft / driveshaft issue.

Prop shaft has play per this video. No visual signs of rust I can see.

What do you think is this amount of play normal or no? When should it be replaced?

https://services.shop-ware.com/uploa...fcrVO-yK3qxSLJ

[m4forum]

I had the same issue few weeks ago. The original shaft has 147k miles. By first inspection when still installed in the vehicle seems like the U-join was worn but no signs of corrosion. After I took it from the vehicle the U-join was ok no play/wear. So the issue was entirely related to the lack of engagement between spline on shaft and the transfer case.
Decided to buy a new shaft with the assumption that the spline on shaft was worn out due the lack of engagement. Find out with a new shaft the play is pretty much the same.
Decided to order a flange that pushes the spline further into the transfer case. Did get it yet. Will report when I get it.
Other alternative is to order the new shaft with longer spline which certainly also address the issue.

[dentprotony@gmail.com]

I am having hard time to keep up with the orders but hit me up at 6016181023 for a proper shaft upgrade

[SunjaKim]

sukhk527 put me onto the upgraded front driveshaft/propshaft from dentprotony@gmail.com and I'm very impressed with the quality.

In addition to the appropriate length spline, the U-joints are higher grade compared to the OEM.

https://f15.bimmerpost.com/forums/sh...&postcount=379

[jbfrancis3]

I bought Tony's upgrade about 20k miles ago and haven't thought about it since - exactly what I wanted. Great peace of mind and nicely made unit.

[LateParty2018X535d]

Important note, please verify for yourself but passing along what I’ve been told regarding proper install of the front drive shaft:

NOTE: DO NOT USE ANTI SEIZE (Contains Metallic Substance) on the Driveshaft Splines at Transfer Case Spline Sleeve.

NLGI NO. 2 Red Grease Was Recommended.

Apparently, this will help to repel rust since it is a grease, but does not contain the metallic substance. This is contrary to the YouTube videos on this install, which show anti-seize, apparently this is not a good idea.