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Old 12-18-2021, 05:34 PM
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RocketyMan RocketyMan is offline
Join Date: Jan 2020
Location: PNW
Posts: 527
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So one thing i've discover on the transfercase is checking the conditions of the clutches. If you remove the actuator and move splines with like a pair of pliers, you should have great "springy" tension. In addition, the thickness of the clutch pack should correlate to about 90 degrees of stop give or take.

I did the same thing of getting a "good used" Tcase from the wrecking yard. I noticed 90 degrees about of actuation.

On my "worn out" Tcase, I noticed that the actuator splines would spin to nearly 180 degrees before it stopped! Needless to say, that Tcase is worn out via the clutch pack.

I would say it is absolutely CRUCIAL the Tcase oil changed every 50k and most likely SOONER if any amount of towing/off roading is done.
2003 BMW X5 3.0i -- MT5, 3.64s final gears, H&R lowering springs, K-Mac bushing kit
2007 BMW X3 3.0Si -- MT6
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