|The teeth (splines) of this ActiveE gear have been grinded away|
Suddenly everybody in the group was buzzing about splines like it was some advanced technology that BMW somehow under-engineered. It's just a simple gear, nothing complicated about it. Question is why are they failing on so many cars, and on a personal level why hasn't mine failed? I have way more miles than anyone else who has an ActiveE, I'm close to 21,000 miles now and the next person (that I know of) is around 13,000. Plus, many of the gears are failing on cars with less than 5,000 miles! Why would that be?
Possible Causes: (my opinion only)
Abusive driving. Maybe the people that have had the gear failure are just really punishing the car beyond its capabilities. There were a few MINI-E drivers who were known to have really abused their cars which is why BMW tightened up the rules and return policies on the ActiveE, making us more accountable for the condition the car is in when we return it. Probability: 5%
Bad batch of gears. It could be that BMW simply got a bad batch of gears that were defective metal. Probability: 15%
The car is too heavy. The drive system for the ActiveE wasn't designed for the ActiveE. It was designed for the 2013 BMW i3 which will be about 1,300lbs lighter than the ActiveE. Could it be the gear just can't handle the stress of applying 184lb-ft of torque to move a car that is over 4,000lbs before you add the weight of the passengers? Probability: 20%
Improper lubrication from factory. All of the pictures of the gears that ActiveE drivers have received from their service departments show the gears devoid of any grease. Gears like this obviously need an ample amount of lubrication or they will grind themselves away in short order. Did the factory just forget to grease some of the gears? Probability: 25%
Lubrication leak/washed away. Perhaps the factory did properly lubricate the gears, but there is either a design flaw that allows moisture to seep in and wash the grease away or there is some kind of faulty seal that allowed moisture in on some cars and that's why their gears failed and others didn't. Probability: 35%
|Rusted & Stripped|
This by no means is an indication that I don't love the car and regret applying for the program, which I don't for a minute. The ActiveE is really a great electric car and just about everyone I know who has one feels the same way. But it is a test car, and the technical deficiencies as compared to a production car do come out from time to time, and I'm going to do my best to write about them, just as I do for all the great qualities the car has.
|This is how the gear should look|
Failing on the ActiveE, Breaking up my mind
Do This don't do That or you'll Break your Splines...