I have an 05 R52 with the 5 speed Getrag transmission. I replaced the clutch today and when I installing the d/s axle, it would not lock in... Finally I looked inside the diff and noticed that the splines were gone! What happened? Is it possible when I jostled the transmission getting it back in that the gear moved it's place and no longer lined up to accept the axle? My car has 222,000 miles and I was replacing the clutch only has a maintenance thing; not because it was slipping or hard to shift. I am going to Gatlinburg for New years and wanted to not worry about the throw out bearing going in the mountains.

 

Does the axle still have a lock clip on the end? There should be a locking c-clip on the end of the axle that locks into the differential carrier.

As for the differential moving while removing the trans, that is highly improbable as it is captive between the two transmission case halves.

Can you get a detailed enough picture that shows more of what's going on?

 

The clip is still on the axle. I removed it to see if the axle would go in further and it did not... This is when I looked and felt the opening on the Trans.. I did not see the carrier, nor did I feel the splines that the axle mates with. I have everything together now and will try pulling apart when I get home and get another look and snap some photos. I know that this is impossible; that's why I'm at a loss. Hopefully I'll look at it again and realize I was mistaken.

 

Pics will help allot. Put a light in that area to take pics as it gets pretty dark under there on the rack or lift.

 

When I first looked at it, I decided to put it back together and forget about it because it was Sunday evening and I needed to get cleaned up so I can go rent a car. Now that I look at it a second time, I see that the holder is in there at an angle. I don't know how, but I assume I broke it whole popping the axle back in... How? I don't know. I've replaced axles before and never have had an issue installing; only removing. Unless it happened removing the axle... Which I doubt.

 

****UPDATE ****

The spider gears on the transmission rate like an eyeball in its socket. All I had to do was remove both axles and rotate the spider gears so they're parallel to the opening ; not perpendicular how they were. All is normal now and my Mini will keep chugging along with the original Motor and Trans with over 222,000 miles!

 

Ah, that make sense, I glad you figured it out. When I did mine , it did not move at all or shift out of place.

Have a great holiday.