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I'm having the same problem with my X5 4.4 sports 2005 but other than occuring randomly, also happens at the worst possible time- on the freeway. Trans goes to limp mode, get all kinds of crazy lights in the dash (multiple faults) such as DSC, 4x4, airbag etc. I have DIS and all the time error points to communication problem DME/alternator, DME shutting down the alternator and thus low voltage to components (explains the multiple faults). All I've had to do is turn the car off and wait for 10 or so minutes and startup again and car runs fine! I removed the alternator (yep, it's NOT water cooled), checked and cleaned all connections, cleaned volage regulator and alternator, installed new battery but all to no avail.
I'm surprised you had a relatively easy time removing and putting back the alternator. I had a nasty time and had to put grease on the edges to push it in while installing it. Removing it was a nightmare. TIS and Bentley manual are all wrong saying to remove alternator straight forward. No, have to first tip it towards driver side then straight forward and out.
I'm also planning to replace the alternator. Cravier BMW dealer quotes $500 with 2 years warranty. I'm also wondering if it's just the voltage regulator ($140) that needs to be replaced.
Please let us know if your issue is resolved after alternator replacement.
Thanks!
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'05 E53 X5 4.4i, '97 E39 528, '07 E92 335i, '16 F86 X6M.
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