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      10-23-2025, 10:15 PM   #24
Runnin'Rich
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Drives: 2009MY E91 328Xi 6MT
Join Date: Sep 2020
Location: British Columbia Canada

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It’s the left CV shaft that is really in the way. The angle of the pinion is 9 degrees further to the left and much shorter on the awd car.

I’m looking into getting a RWD pinion cut with the 9 degree difference further up the pinion shaft so it’s shorter. Unfortunately the gear teeth size is totally unusual so it’s probably going to be a struggle to find a machine shop which would do it. Let alone at a reasonable price.
I might be better just get a fully custom matching rack and pinion made from scratch using standardised gear teeth sizes.
Although I’m concerned there will be backlash and therefore some steering ‘play’ felt at the steering wheel.
Maybe the compression spring and the helical teeth eliminates that problem?
Appreciate 1