e46 chassis tear/repair

[JaPbOy!]

Hi Guys,

have any of the e46 manne done this to their cars. I'm sure you are all well aware of how the chassis tear because it was something that was common on the 36s as well.

My big bro purchased a e46M and is in the process of doing the fix. Just wanted to know if any of you did it yourselves.

Will update pics soon.

I do see there are many DIYs on the interwebs as well showing a step by step guide. before we came across it though, we ventured into the unknown, being more toy orientated and all...

so far so good, hoping to complete it by the end of today, or by tomorrow for the latest...:rollsmile::rollsmile:

il soema add all the things that we did since he bought the car a month ago, he only drove it for 2 days and decided that thats exactly how a M SHOULDN'T drive...:thumbdo::thumbdo: and then came the complete tear down of everything that was even SLIGHLTY wrong...

 

[mo_s]

I didn't even know about this, where does the tear happen? :fencelook:

 

[calypso]

Will be interesting to see a DIY repair. Between this and vanos hubs, they are my greatest fears for the e46.

For the e36 the only thing I fear is that the battery might be flat

 

[netercol]

although this is the famous subframe tear on e46, i have never seen it on a car.. not even on 330d's which put a lot of torque through their subframes..

think it was only the very early (98-99) e46 325i and 328i that suffered from this?

 

[calypso]

To be honest, the dealer also says that the cracks issues in E46s is over blown, and plenty rack up many miles without issue.
Still doesn't stop me from kakking myself every time I hear a squeak or creak.

 

[JaPbOy!]

although this is the famous subframe tear on e46, i have never seen it on a car.. not even on 330d's which put a lot of torque through their subframes..

think it was only the very early (98-99) e46 325i and 328i that suffered from this?

nope it happens on e36s and e46s as well. i think a guy that was possibly on this forum ( a friend of mine) had a blue 36 and his tore too...

il upload pics once i save them to my PC. The previous owner of this car defo never looked after his car or couldn't afford to maintain it...

this is how we kind of stumbled upon it.
drove the car and had a horrible irritating knocking sound. drove the car up the stands. pulled on drive shaft and it seemed as if the diff bearings were worn.

Called Zeemax to ask what it would cost to have it replaced, they asked whats wrong, was told to them about the knocking noise, then they said that its a common thing and to bring the car in because the chassis usually tears and if thats the case then it will need to be welded up etc.

after that, we drove the car up again, had a squiz and alas!! in its poons. did some interwebs research and voila, the start of "projectM" was born.

From there, the rear subframe was romoved completely, and so was the box since we were there, and also because the release bearing made it sound like the motor had a bearing knock:flyfun::flyfun::flyfun:

from what can be seen, it must have been a golf mechie that worked on this car coz damn!! i've never seen such bad workmanship on a car that expensive!:argh::argh: sensors wires hanging loose, EGT sensor wires ripped out cos it was hanging loose etc etc etc.:thumbdo::thumbdo::thumbdo:

anyways, glad the decision was made to go all out one time and fix everything while at the bottom...

moral of this reply...it does happen, i have the pics to prove it:thumbs:

---

To be honest, the dealer also says that the cracks issues in E46s is over blown, and plenty rack up many miles without issue.
Still doesn't stop me from kakking myself every time I hear a squeak or creak.

even with my 330 im like this because of what iv seen.

on a side note though, why would the dealership have an "upgraded" part if it wasn't that big a deal...:nonono:

 

[Ralf*]

We also had an E36 M3 in our shop a month or so ago, and it also had a massive tear on the chassis front right, causing the entire front right suspension to be loose and scraping due to apparent movement of wheel.

My suspension/wheel alignment technician (RMI approved) hauled out the big tools, (hydarulic press etc) pulled/pushed clamped and then with the car back into alignment, welded up the chassis....before redoing the wheel alignment properly and solidly.

 

[Crash_Nemesis]

I just did this repair to my e46 M3 last week. Leonard at Dent Doctor got a professional welder to weld up the cracks and to weld in reinforcement plates. We also welded in a brace on the boot to connect the two rear shock towers, this brace now takes all the abuse that the chassy/subframe used to. Speak to Leonard about it. I will upload pics soon, I'm in Durban on business at the moment so cannot upload yet. I have shot tonnes of video documenting the repair job. No more metal stress sounds.

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Ps. Would like to hear more about this release bearing that makes the engine sound like it has a bearing knock.

 

[JaPbOy!]

I just did this repair to my e46 M3 last week. Leonard at Dent Doctor got a professional welder to weld up the cracks and to weld in reinforcement plates. We also welded in a brace on the boot to connect the two rear shock towers, this brace now takes all the abuse that the chassy/subframe used to. Speak to Leonard about it. I will upload pics soon, I'm in Durban on business at the moment so cannot upload yet. I have shot tonnes of video documenting the repair job. No more metal stress sounds.

the reinforcement plates we cut out already after making templates. we also thought about making a brace from the rear point on the left plate to the right one to also handle the stress. i'll appreciate any pics you might have to upload to see how it was done by the pros.:thumbs::thumbs:

 

[ChrisBrand]

My subframe ripped out. Had zeemax repair it. Took a week and cost around R9 000. Have photos if anyone wants to see how it looks wen it rips. I know a bunch were recalled in the states to fix but none in SA


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[calypso]

My subframe ripped out. Had zeemax repair it. Took a week and cost around R9 000. Have photos if anyone wants to see how it looks wen it rips. I know a bunch were recalled in the states to fix but none in SA


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BMWSA actually did fix a couple on the house if you complained enough about it.

Im thinking of buying a Turner Motorsport reinforcement kit and some AKG bushings just in case this ever happens.
Rather have it on hand then have to wait for import.

 

[cOlDFuSiOn]

I truly did not know that this is such a common problem.. Wow that must be a scary prospect driving one of these in the hope that next creek is not your last! Looking forward to the DIY fix on this! :thumbs:

 

[zaleonardz]

The problem is that if you allow this to happen, simple re-welding wont cut it.

Crash'es car has been repaired before where the welding was touched up.

The results however is that the entire subframe not only cracked all around the spot weldings, but it actually TORE the body in several places as well.

This essentially means, that for structural support provided by the sub frame virtually means nothing....

This is why we could not just reweld the floor,

Technically speaking, the floor had to be replaced.

However, just the boot floor comes in 2 pieces.

I did a quote using original BMW parts, and it was way into the 25k, with MOST of it being on parts, ie metal plates.

What upsets me is that even though BMW KNOWs they screwed up, they do not subsidise the replacement parts.

Lets wait for Crash'es photo's to see what we actually did...

 

[frikkieh]

There is a nice write-up on this here

There is a kit they sell consisting of:

1. Two 12mm x 1.5 bolts
2. Two front subframe mounting point Reinforcements
3. One Right rear subframe mounting point Reinforcement
4. One Left rear subframe mounting point Reinforcement
5. Two cross member spacers
6. Two trunk block off plates
Applications: 1999 - 2005 (E46 3- series and M3)

Was concerned that my 323i has this but fortunately it does not have that much power :fencelook:

 

[calypso]

That being said, crashes car makes more power then most, so will put even more strain on an already weak parts. For a car like his, a convertible floor should be put in.

 

[JaPbOy!]

The problem is that if you allow this to happen, simple re-welding wont cut it.

Crash'es car has been repaired before where the welding was touched up.

The results however is that the entire subframe not only cracked all around the spot weldings, but it actually TORE the body in several places as well.

This essentially means, that for structural support provided by the sub frame virtually means nothing....

1.This is why we could not just reweld the floor,
Technically speaking, the floor had to be replaced.

However, just the boot floor comes in 2 pieces.

I did a quote using original BMW parts, and it was way into the 25k, with MOST of it being on parts, ie metal plates.

2.What upsets me is that even though BMW KNOWs they screwed up, they do not subsidise the replacement parts.
Lets wait for Crash'es photo's to see what we actually did...

1. correct! hence having to weld in reinforcement plates as well as a strut

2.Absolutely!! apparently, they still partly deny, although as i stated before, the is a "upgraded" replacement part. i have the part number too...

 

[moranor@axis]

if you drive had there is a good chance of this happening to a pre F/L e46 my 323i ripped so eve 245Nm is enough to do the job...