Somehow must have tweaked a thread at the end of the output shaft after removing the nut. I have a thread file but it’s one of those double ended ones that would be just short enough to work inside the bell housing (8.25”) but the blank centre sits right over the shaft so NFU.
Can’t source a shorter file - unless you folks know better?

Failing that I’ll have to take the intermediate housing off to add to my bad karma bank.

Try a needle file set also known as mini files or hobby files. If needed they can be shortened and they aren't that dear.
Regards Martin.

The mini files would have worked great, but I got impatient and modded an old swing arm pivot lock nut tightened with vice grips. Threads straightened.
Cheers, Stu

Over the years I've placed diagonal cuts into high tensile nuts and bolts and used them to clean up threads. It's worked most of the time.
Regards Martin.

tinyspuds wrote:Failing that I’ll have to take the intermediate housing off to add to my bad karma bank.

Don't... just don't... unless you ever really, really have to. BMW in their infinite stupidity used Torx30 bolts to hold the intermediate housing on. It's an impact driver and huge amounts of patience job - don't even think about trying to unscrew them with a torx driver. If it ever does have to come off, replace the torx bolts with bogstandard Allen heads. They do fit.


Oh yes - and there's a hidden one, just to frustrate you even more.-

Dai wrote:Don't... just don't... unless you ever really, really have to. BMW in their infinite stupidity .  .  .

The implications of being a buyer of and investor in an infinitely stupidly-made product are too unsettling to contemplate so I won't contemplate them.

Dai wrote:

tinyspuds wrote:Failing that I’ll have to take the intermediate housing off to add to my bad karma bank.

Don't... just don't... unless you ever really, really have to. 

Well, if you’re sure...

Laitch wrote:The implications of being a buyer of and investor in an infinitely stupidly-made product are too unsettling to contemplate so I won't contemplate them.

 

Dai wrote:

tinyspuds wrote:Failing that I’ll have to take the intermediate housing off to add to my bad karma bank.

Don't... just don't... unless you ever really, really have to. BMW in their infinite stupidity used Torx30 bolts to hold the intermediate housing on. It's an impact driver and huge amounts of patience job - don't even think about trying to unscrew them with a torx driver. If it ever does have to come off, replace the torx bolts with bogstandard Allen heads. They do fit.


Oh yes - and there's a hidden one, just to frustrate you even more.-

Holy Mackeral there, Andy!  Having removed the intermediate housing on three different bricks I didn't realize those screws were such a problem.  Ya lurn somthin' new every day.