Help needed finding Transfer Case Parts

[DSSA]

Hello, all.

I picked up an '01 X5 4.4 this afternoon, in hopes of replacing my aging, current dog-hauler, my '00 528i Touring (240K and getting tired).

Previous owner was a great guy, and a friend of a friend.

However, he sold it due to power transfer losses and grinding come from the transfer case area.

He had recently had it "repaired" by a local BMW dealer due to a stripped spline on the front output shaft, and their fix was to just put a new shaft in it.

I'm thinking that the output shaft (driven gear) splines of the t-case were half shot as well, and while the new, stock-length shaft temporarily band-aided the issue, I'll be in need of fixing it correctly before utilizing the vehicle.

I've sourced the replacement, longer spline repair kit (I have no issues with cutting or welding it in), and am planning on doing the chain and updating the gear on the actuator while the case is out on the bench. However, I cannot find a decently priced replacement driven gear so that I can take care of the spline issue. Cobra Transmissions is the only place I can find them, and with A) comparing their prices to other places selling the shafts and repair splines, they're about double the pricing, and B) if I'm going to drop $400 on just the driven gear for this thing, I'd rather take the time to find a good condition transfer case for nearly the same price and just refresh that one.

Using a longer spline is great, and should have been done by the factory (although the removal of the shaft while the t-case is in the car may be part of the reason), but sticking fresh shaft splines in a gear with half of the length of the engagement splines already wiped out puts you right back to square one of only having a limited meshing area.

I'd rather replace the typical wear items on the unit while I have it out the first time.

Does anyone know of any other sources for the NV125 driven gear?

Thanks for any help!

Josh