Searching for anyone who has installed the 650i differential cover

[Pig Farmer]

Originally Posted by Yeineken

Updates on the install?

I hit a couple snags. The M14x1.5x120 bolt is definitely to short. I received the 130mm BMW bolt and it fits perfectly, but the bolt is grade 8.8 which is a little weaker than grade 10.9. I found a place on line that carries M14x1.5x130 grade 10.9 bolts. I plan on ordering one tomorrow. In addition, I ordered the two front M3 differential bushings but only one arrived in the mail. I figure the install will take place next week.

Here's a picture with the M14x1.5x130 bolt:

[gap]

Diff, cover, bushings are here. Long bolt and Dimple Drain plug will be here
Friday and will have it installed next week.
The bottom of the 650i cover extends 1.25" further down making this the new
low point under the car. Might be flossing roadkill out of the fins.

[Pig Farmer]

Originally Posted by gap

Diff, cover, bushings are here. Long bolt and Dimple Drain plug will be here
Friday and will have it installed next week.
The bottom of the 650i cover extends 1.25" further down making this the new
low point under the car. Might be flossing roadkill out of the fins.

You're right... it's definitely going to be the low point. Since it sits only a few inches behind the rear axel, I think we should be okay going up and down inclines, declines, speed bumps, ect. (I hope). I also don't think it should be much lower than the M3 diff cover, or the VAC diff cover. For example, the shorter of the two VAC diff covers measures 11" from top to bottom. The 650i cover is a little less than 11.25". I guess we'll find out.

BTW, what did you do about the spacer? Did you find one off the shelf, or did you make one yourself?

[Yeineken]

This thread needs an official parts list once a install has been completed

[Pig Farmer]

Originally Posted by Yeineken

This thread needs an official parts list once a install has been completed

Agree. I think we're getting close.

[gap]

A good friend of mine owns a auto repair shop with a history of working on performance cars. He has all the tools and knows how to fabricate what is needed and is OK with me doing all the leg work getting parts and bringing them to him.
I'll post up the install when finished next week and list what was used.

[gap]

I am ordering these to make the spacer. Hole will need to be enlarged then cut to length. Any machine shop could easily do it.

[gap]

Got started on the project and all is going well. He had to remove the 3 fins on the left to clear the exhaust. He used a band saw to cut most of it off then a milling machine to finish it up. He is also replacing my 6.75 year old water pump and installing M3 sub-frame bushings so will probably be a day or two more before I can post the finished pictures.

[Pig Farmer]

Originally Posted by gap

Got started on the project and all is going well. He had to remove the 3 fins on the left to clear the exhaust. He used a band saw to cut most of it off then a milling machine to finish it up. He is also replacing my 6.75 year old water pump and installing M3 sub-frame bushings so will probably be a day or two more before I can post the finished pictures.

Looks like you beat me to the punch. I was just out in the garage with a template trying to figure out the exhaust clearance. I wasn't sure if I could get away with removing just 2 fins, or 3. Do you happen to have a picture of where you cut the fins? Did you trim the fins following the outline of the cover, and did you have to cut down the first 2 fins? Thanks.

[gap]

Camera is at his shop, I'll get it tomorrow and post what I have.

[gap]

Getting close, would be finished if it weren't for the sub-frame bushings.
Back two are done.
Diff bushings went in with no problem.
List of what was used. Prices Include shipping to me.
MFactory Diff - MF-TRS-05E9230P $2,279.95
650i Diff Cover ESC Tuning - ES#56046 $126.6.84
Whiteline Diff Bushings KDT919 $94.81
Dimple Magnetic Plug - M22 X 1.5 X9 $40.90
Redline 75W90 Gear Oil $31.90
Bellmetric Bolt BH 14 X 1.5 X 130 - Hex Bolt 10.9 $15.49
Aluminum Spacer- Granger 5GNZ6 $26.25
Core Return Shipping to MFactory $68.00
Subtotal $2,684.14
- Core Refund $500.00
Total parts without install labor $2,184.14
Should get the car back tomorrow and will post finished pictures.

[Pig Farmer]

Originally Posted by gap

Getting close, would be finished if it weren't for the sub-frame bushings.
Back two are done.
Diff bushings went in with no problem.
List of what was used. Prices Include shipping to me.
MFactory Diff - MF-TRS-05E9230P $2,279.95
650i Diff Cover ESC Tuning - ES#56046 $126.6.84
Whiteline Diff Bushings KDT919 $94.81
Dimple Magnetic Plug - M22 X 1.5 X9 $40.90
Redline 75W90 Gear Oil $31.90
Bellmetric Bolt BH 14 X 1.5 X 130 - Hex Bolt 10.9 $15.49
Aluminum Spacer- Granger 5GNZ6 $26.25
Core Return Shipping to MFactory $68.00
Subtotal $2,684.14
- Core Refund $500.00
Total parts without install labor $2,184.14
Should get the car back tomorrow and will post finished pictures.

Thanks for the pics. I made my cuts today. Wondering how the install went?

[gap]

Will probably be monday now, he got side tracked on another job.

[gap]

Got it back today, it is a close fit and I may remove a little more material to get a bit more clearance but they are not bumping into each other now.
With the spacer if you are going to use the same bushings then measuring the difference between the 650i and stock cover should work. With different bushings the size of the spacer may be different, he suggested torquing the drive-shaft and front diff bushings then measuring. Can't hear any diff whine but the front seal where the drive shaft attaches is leaking so it isn't finished yet

[Pig Farmer]

Originally Posted by gap

Got it back today, it is a close fit and I may remove a little more material to get a bit more clearance but they are not bumping into each other now.
With the spacer if you are going to use the same bushings then measuring the difference between the 650i and stock cover should work. With different bushings the size of the spacer may be different, he suggested torquing the drive-shaft and front diff bushings then measuring. Can't hear any diff whine but the front seal where the drive shaft attaches is leaking so it isn't finished yet

Great pictures, and sorry to hear about your front seal. Out of curiosity, what axle back and mid pipes are you running? BMW PE?

[Dackelone]

@gap nice pics and thanks for updating this thread.

Don't forget to change your diff oil in 1,200 miles or so. It never hurts to flush out any metal bits left over from the install.(from grinding the inner case/core, etc)

[gap]

BMW PE with Maddad midpipes. Great sound when accelerating hard and quiet while cruising at highway speed.

Local parts store had a seal in stock so he said it would be easy to change out tomorrow morning.

[Pig Farmer]

Originally Posted by gap

BMW PE with Maddad midpipes. Great sound when accelerating hard and quiet while cruising at highway speed.

Local parts store had a seal in stock so he said it would be easy to change out tomorrow morning.

Awesome. BTW, PE with Maddads is my exact setup. Sorry to ask so many questions but were you able to reinstall the support brace that sits in the middle of the mid pipe? I was never able to line up the bolt with the Maddads so I've been running without the brace. Haven't had a problem in over two years, but always wondered if it was just my mid pipes.

[gap]

Originally Posted by Pig Farmer

Awesome. BTW, PE with Maddads is my exact setup. Sorry to ask so many questions but were you able to reinstall the support brace that sits in the middle of the mid pipe? I was never able to line up the bolt with the Maddads so I've been running without the brace. Haven't had a problem in over two years, but always wondered if it was just my mid pipes.

No problem with the mid-pipe brace, they supplied a longer bolt that worked just fine. Will take a picture of it tomorrow.

[gap]

My friend changed out the front seal Sunday and took off a little more material to get a little extra clearance from the exhaust. He also took a picture of the magnetic drain plug that is covered after just 30 miles. Will change the oil at 1,000 miles but will probably check the magnet again before then.
I have noticed a very faint whine while decelerating in gear, doesn't bother me at all.

[Pig Farmer]

Originally Posted by gap

My friend changed out the front seal Sunday and took off a little more material to get a little extra clearance from the exhaust. He also took a picture of the magnetic drain plug that is covered after just 30 miles. Will change the oil at 1,000 miles but will probably check the magnet again before then.
I have noticed a very faint whine while decelerating in gear, doesn't bother me at all.

Success!

[Pig Farmer]

Finally had a chance to take a picture of the install. So far, no issues at all.