Achilles Heel: BMW E46 M3 subframe

    Internet scaremongering or an inevitable big bill? We set the record straight in the first of a new series

    3y ago

    362.9K

    Yes, we ran an E46 M3 story yesterday, but we make no apologies for coming back to that car today because it’s inspired us to create a new series looking at some our favourite cars’ biggest gremlins, and whether those gremlins are really as common and pricey to fix as internet rumours would have you believe. This week it's the M3.

    The accused

    BMW M3 (2000-2006)

    The rumour

    All E46 M3s will suffer from expensive cracked rear subframe mount problems.

    The Experts

    BMW M guru - Dan Norris (Munich Legends, www.munichlegends.co.uk), E46 M3 Subframe Crack specialist - James Redish (Redish Motorsport, www.redish-motorsport.com).

    Is it fact or overblown internet fiction?

    Dan Norris (DN): If you'd asked me about this five or six years ago I would have said don't believe what you read – it's just another forum myth – then, suddenly, I started noticing all the CSLs we looked after were coming in with boot floor cracks, even cars with less than 18,000 miles.

    James Redish (JR): We started repairing M3s back in 2011. Every year I keep thinking it's going to get quieter but this is our busiest year yet. Since we started we've done more than 147 rear axle carrier panel repairs and we're fully booked up until the end of September.

    Which cars are affected?

    DN: All of them. They all either need doing or have been done already.

    JR: There are rumours that SMGs are immune and convertibles don't suffer cracks – but they all do. There are E46 M3s of all descriptions in my workshop right now.

    When will it happen and why?

    JR: There's no given mileage when it starts to happen – no science or pattern. The only thing we can be fairly sure of is the more aggressively you drive your car the more likely an M3 will develop cracks and severe damage.

    www.redish-motorsport.com

    www.redish-motorsport.com

    Launch control and snap first-to-second changes are particularly damaging because it's not rot that’s the problem. The cracks are stress fractures.

    The reason is the entire rear axle is mounted on just one panel and it's a very thin stamped sheet. It only has spot and MIG welds holding it together and, for some reason, BMW fitted it from underneath the car so it's always at a disadvantage, battling against the weight of all those components, gravity and the immense forces it's subjected to.

    Severe cracking, viewed from inside the boot (www.redish-motorsport.com)

    Severe cracking, viewed from inside the boot (www.redish-motorsport.com)

    Cars built from October 2004 have a modified rear panel. Additional spot welds and MIG welds that have been added, all in the left-hand corner, where the problems start. Those cars’ modified panel doesn't flex quite so much, reducing the risk of those hairline cracks.

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    What's the solution?

    Redish repair kit (www.redish-motorsport.com)

    Redish repair kit (www.redish-motorsport.com)

    JR: We offer two solutions: A DIY method that costs just £156 for the subframe reinforcement plate kit we've engineered. Or we can undertake the work ourselves - something most of our customers opt for. That costs £1434 (inc VAT).

    Repair plate welded into place (www.redish-motorsport.com)

    Repair plate welded into place (www.redish-motorsport.com)

    It takes eight hours to drop the rear axle, suspension, exhaust, handbrake, fuel pipes and ancillaries, plus time to strip all the boot to gain the access to we need.

    Repair sealed and painted (www.redish-motorsport.com)

    Repair sealed and painted (www.redish-motorsport.com)

    Once stripped we use a specially adapted borescope camera to locate the smallest hairline cracks and fractures, and we check 155 spot welds for failures.

    Once we locate a problem area we remove the underseal and strip back to bare metal before finally beginning the repair. All in all, our process can take 4-8 days.

    A fully repaired and detailed M3 underbody (www.redish-motorsport.com)

    A fully repaired and detailed M3 underbody (www.redish-motorsport.com)

    DN: We charge around £1800 (+VAT) for a repair but luckily the cracking problem has coincided with M3 values rising dramatically in the last couple of years. Buyers are well aware of the problem and will ask to see proof of a repair – if you want to keep the value of the car you have to deal with it.

    JR: It's a shame that BMW has never properly responded to the issue in the UK (editor’s note: it did fix some cars before they’re tenth birthday) although owners successfully sued, and won, a case against BMW USA over the issue. I guess us Brits don't like suing people. bit.ly/2oOHvSU

    Hmm, maybe we'll make do with a nice 328i coupe

    JR: Are you kidding? The ’98-00 325/328i was even worse – there are even fewer spot welds than on an M3. There's only one E46 model that isn't affected, the E46 Compact - we've never had to repair one.

    It has a completely redesigned rear axle carrier panel to the coupe, saloon and estate – something to do with packaging a spare wheel. They're tough little things, but, yeah, not very desirable.

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    Comments (36)

    • There is always science.

        3 years ago
    • Great article Chris. I look forward to the instalment about S2000s so I can see what my next big bill is going to be!

        3 years ago
    • Z3s also suffer from this issue.

        1 year ago
    • All bmws have there problems

        3 years ago
    • Nice to know that cars made by the "Mighty BMW" also have problems contrary to what their fanboys say!

        3 years ago
      • It's those so called 'fanboys' that are keeping thsese cars alive by ensuring that repairs like this are done. BMW are just like all other manufacturers, all their models have inherent issues. I've never met any BMW owner who has said his car...

        Read more
          3 years ago
      • I've only met one in all fairness, and working in the motor trade you meet all sorts of people! 😂 I'm talking mainly about the trolls who loiter round places like car throttle etc.

          3 years ago

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