I bought a r53 with the passenger axle broke in half, so I bought a new axle and was unaware of the difference between the automatic and manual transmission. The manual axle being longer.
So I put a automatic axle in and it broke in half just like the other. So I realized my mistake and bought a axle for the manual transmission. This axle was longer and when I installed it everything looked fine, went full turn each way and spun the rotor in the air and no binding of the cv axle.
I proceeded to try and drive it out of the shop, all was going good no sounds or anything. But when I went to go around the block… Bang. The inner cv joint broke again. I’m really not sure as to why it did this. The suspension pieces don’t look bent in any way for it to pull the axle out of the joint. Any suggestions on to why it might be doing this? Thanks.



What happened to the axle after I tried to drive it out of the shop



The axle after I took it out of the car

 

Forgive me if it's seems like a stupid question:
Had you had any difficulties in mounting the support/carrier bearing bracket?
I have an '04 R53 but have yet to replace my axles but I recently discovered the right (passenger side) carrier bearing mount bolts had mysteriously started backing out/loose.
I caught it just in time. No damage to the bolts or carrier and no separation of the cv joint.
In my case: I only discovered it as I had noticed some slight vibration at take off and low rpms while shifting

Perhaps the large inner "C" clip/spring clip is not seated property in the carrier bracket bearing?

Just a thought.

EDIT: ModMini has a pretty good video on

 

why do I have the feeling the answer is going to be, "what support carrier bearing bracket?" ...because it's apparently no longer on the car...

That aside...

Discussions on this board have noted that aftermarket CV axle assemblies aren't all built the same; some not even to acceptable OEM specifications and tolerances. Apparently this is a corner that cannot be cut and OEM quality is a must-have. Most of our vendors sell 'OEM quality' which means by the manufacturer, in the same factory, but without the premium 'Muh Gen-U-Ine BMW/MINI' stamp on it, and sold at a substantially lower price than the stealership. Just food for thought in case it applies...

 

Either genuine MINI or GKN, these are the only ones worth buying.