SUPER complete Rear Suspension overhaul

[99MPower]

To preface this thread, some of this work was completed last year

Here is a list of ALL parts used

(4) Lemforder Balljoints #2 and #3 part #33326775551 $35 each ($140)
(3) Diff bushings AKG Poly $120
(2) AST monoball RSM's (came with my 4200's) $280, but I got them with my suspension
(4) Powerflex Purple Subframe Bushings (Bimmerworld) $145
(6) McMaster Washers $20
(2) E90 Front suspension bolts #3 part #31106769908 $15
SPC Camber Arms $180
SPC Camber Arm spacers $45
AKG Swaybar Reinforcements (BEST reinforcements IMHO) $35
(2) Upper/Inner bushings #6 part #33321092247 $20
(2) Powerflex RTAB Bushings (Bimmerworld) $75
(2) Outer CV Boot kits #5 part #33217840673 $32
(2) Inner CV Boot kits #6 part #33219067806 $43
(4) Tubs of Redline CV2 grease $10 each $40
(2) FAG Rear Wheel Bearings #3 part #33411090505 $45 each $90
(2) Axle Nuts #4 part #33411133785 $5
(2) Snap Rings #2 part #07119934755 $5
(8) Cable Holders #23 part #33181181218 $5
RTAB Pocket Reinforcements (Bimmerworld) $40? couldnt find on website
(2) Crush Washer for diff #7 part #07119963355 $2
(1) Diff Gasket #3 part #33111211708 $2
(2) Royal Purple 75w140 gear lube $40
(12) Halfshaft to Diff Bolts #3 part #33211227664 $24
(6) Reinforcements #2 part #33211209543 $10

TOTAL $1133 without counting welding/press costs and paint/powdercoat. Also I did NOT include the RSM's into the cost, but EVERYTHING else is

To preface this, I rebuilt my new FAG rear wheel bearings using a DIY I found on BFC here. This thread also talks about the benefits of taking the bearing apart and repacking with new CV2 grease

http://forums.bimmerforums.com/forum....php?t=1231517





Also, I rebuilt my halfshafts and made my own DIY which is also in this section.

http://forums.bimmerforums.com/forum....php?t=1398300





This huge project was started because I was running the Powerflex purple rear subframe bushings and knew there were issues with the washers cupping. I ran into this thread and this issue was discussed and this is where I got the info for the Mcmaster washers and e90 front suspension bolt

http://forums.bimmerforums.com/forum...frame+bushings

Also, my halfshaft were leaking some fluid from the inner cover, and I knew there wasnt as much oil in there as there should be from an incident last year.

To complete my overhaul, my Bimmerworld swaybar bracket reinforcements were cracking and I knew I needed to get this fixed, and through some research and a visit to the "mad greek" at AKG (shop is 15min from my house), I found out the AKG swaybar reinforcements were by far the best. Also, after last years bushing overhaul, I didnt do the rear wheel bearings, and I wanted to knock them out as well.

On to everyone's favorite part, the pictures

Some pics from last years overhaul with the bushings


















At this point, I didnt have access to a press so I took all my new parts and brought everything to a local shop and had everything pressed in
















After all that work, I ran some track events, and when I was inspecting things this fall, I found this









To say the least I was not happy that my Bimmerworld reinforcements were cracking apart






Onto some pics from this years tear down, overhaul, and reassembly

[99MPower]

SUPER REINFORCED Diff Mounts





















































ALL DONE

[REHaas]

Holy ish!

Good work Cal!

[99MPower]

Forgot to add pictures of the RTAB pocket reinforcements

[das borgen]

I like? No! I love

[LUSTR]

One of the top threads on BF.c for sure! One day I will follow this to each and every word. Great work bro.

[mtechnica]

Good work, to say the least

[M3_MadBimmer]

This is the only way to do a rear end overhaul. Once and thats it

[95s52]

Very nice work! How many miles does your car have?

[Brent 930]

Very nicely done. You shouldn't have any more issues.

I also got the RTA pockets welded up with BW's kit before finishing my project. Did you have stress cracks around the threaded holes? I didn't have any and just had the plates welded in there. I'm assuming that will prevent any cracking.

Also could you explain the reason for the E90 bolts?

Thanks

[99MPower]

Originally Posted by 95s52

Very nice work! How many miles does your car have?

99,500miles The car is tracked and auto-x'd and all the bushings/bearings/balljoints were SHOT

Originally Posted by Brent 930

Very nicely done. You shouldn't have any more issues.

I also got the RTA pockets welded up with BW's kit before finishing my project. Did you have stress cracks around the threaded holes? I didn't have any and just had the plates welded in there. I'm assuming that will prevent any cracking.

Also could you explain the reason for the E90 bolts?

Thanks

RTA pockets were PERFECT when I had the reinforcements welded in. No issues there

E90 bolts are required due to using the thicker McMaster washers. Also a nice side effect is that they dont have that nut on the top.

[Xiphos]

What did it all end up costing you if you don't mind?

[99MPower]

due to the fact that it was done in two stages I'm not really sure... I could "guess" though and might guess there is almost $1000 in just parts there


I'll update my first post with prices when I get chance. Really depends on if u have a press, access to a press, make your own, or pay someone. Also, the welding required (paying someone else, have access to a friend, or yourself)

updated first post.... ALL parts except the RSM's (came with 4200 kit)

$1133 in parts without the welding/press cost, and paint/powdercoating

This can be cheaper if u use OEM parts where I use "performance" or just used you old lower camber arm and bought new inner bushings instead of getting adjustable ones like I did. I even got a cheaper set and still $180 added cost

Here is another overhaul that I helped with that wasnt nearly QUITE as extensive, but some other pictures

http://www.m3forum.net/m3forum/showthread.php?t=263751

[SneauxM3]

Your bent lwr control arm is nothing, muah ha ha haaa.....this actually sucked kinda

[99MPower]

Originally Posted by SneauxM3

Your bent lwr control arm is nothing, muah ha ha haaa.....this actually sucked kinda

ouch...

my "bent" lower arm is was triggered that first overhaul

[MBe36]

Can you explain how different the ride is?

[SneauxM3]

You daily your car too don't you Cal? I've been debating subframe bushings or not depending on transfer of noise. Wanted to keep them factory but do the poly diff mounts.

Any input on how yours feels

[99MPower]

felt great with no issues, but mine is stripped and I have a pretty high tolerance for that stuff

the car is literally GLUED to the road.. I'll find out this week once I get my last order of stuff in from CMUZZY

[KnudsonM3]

Copied it and saved the DIY into a word file


So when are you doing mine?

[99MPower]

you can copy and save, but the links would all be gone....

[KnudsonM3]

Originally Posted by 99MPower

you can copy and save, but the links would all be gone....

Links are all there....

God bless windows 7


OT: did you hear that we can now use Facebook, myspace on our gov comps?

[///Montizzle]

Doing WORK son

[RagnarDanskjold]

I ruff u.


I'm at 225k/mi and I've been planning a rear end rebuild for a while. This is beyond inspiring. It's damned informative and a great write-up!

Thanks for sharing this.

[Mr Estoril]

Now I see what your little secret with the powder coating was. Good work!

[99MPower]

Originally Posted by ///Montizzle

Doing WORK son

thanks Monte

Originally Posted by RagnarDanskjold

I ruff u.


I'm at 225k/mi and I've been planning a rear end rebuild for a while. This is beyond inspiring. It's damned informative and a great write-up!

Thanks for sharing this.

no problem.. With as much work as I have into my rear suspension, I figured it would be a shame NOT to share everything, and all the information


Leif... I dont touch either with a 10ft pole.. you realize they can track EVERYTHING you do on the government computer