Firstfives.org

The repair site and manuals only say to remove them, noting to use, " Curil," to put them back on after installing the boot kit.

I have to assume that's some kind of liquid weld glue, because no gentle tapping of the cap edges is doing anything.

What's the trick to avoiding notches, bending the edges, mangling the caps trying to remove them ?

Are you talking about the fasteners with the allen head caps?

If so, using a precisely sized (confidence in quality German made) bit, with some inward pressure and care should help. But if they're really rusted in there, it just may not be possible to get them all out in perfect shape. Then you can grab the heads externally, drill, whatever it takes. And of course, then replace the bolts with new.

Maybe that didn't answer the right question. Maybe it did.

KenB

It's like contact cement. I've had to persuade them a bit but nothing scary.

The covers / caps on the cylinder ends of the half shafts, gold zinc plated. Must be removed to grease inside, or install a boot kit, or purchase rebuilt half shafts that do not include the covers.

Only because the metal (edges) are so thin, the caps fit so tight. I'm thinking tapping a screw driver on the edge risks notching, putting nicks in the edge.

I'm going to try a brass hammer handle, flat bottom, tappy tapping around the cover until it comes off. Or maybe get a torch, burn the garage down and take up roller blading.

A brass drift and a hammer works well for me. I've also used a screwdriver without ill effects.

Armed with your confidence, and a dose of, " Enough aready," I whacked on the edges as advised.

Rather anti-climactic. They just fell off. No damage.

Man, the grease in those puppies is some black nasty stuff.

I admire your patience - i usually find out the hard way whether brute force is the answer (i'm getting better with experience).

Any chance you can document the process of overhauling the shafts?

http://www.malloc.nl/BMW/635CSi/pages/en/index.html

Because the E12 and E24 (before '82) share so many component parts, I like this site for the much cleaner photos with the instructions.

If your shafts are in good shape, bellows intact, you can leave them alone or, depending upon your concern for their mileage, knock the caps off and repack with grease.

A ripped bellows, the kits are available from web parts places. Like twenty bucks. Then you'll get to play in the super black grease, learn how to press the spline out of the end(s), curlex the caps back on.

Or, you can copy me. Spend fifty more bucks each, trade the greasy ones for candy gold rebuilts, and let somebody else fool with the spline hitting and grease packing.