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

[jdstrickland]

Have you seen Welcome to realoem.com |bmw parts | bmw parts catalog| bmw epc! or Penske Parts - Parts Catalog for BMW & Mini

Also, if you know which t-case you have, you should be able to do a Google search and find YouTube videos, and a host of other resources.

Nevermind, I should be asking advice of you...

[jdstrickland]

Let me pose a hypothesis, The previous shaft that was worn also killed the gear that it goes into, and now the new spline has a 1/4" of good gear that is now also bad because it is so small it cannot do the work that is required.

All you need is a new spline -- you already have it -- and the output gear that it goes into. With new splines on the output gear, and longer splines on the shaft itself, you should be good to go, and no other modifications needed. You do not need to overthink this one.

[upallnight]

To answe the OP's original question

Automatic, Standard Transmission & Transfer Case Rebuild Kits Cobra Transmission

BMW X5 - NV125 : , Cobra Transmission

[DSSA]

Originally Posted by jdstrickland

Let me pose a hypothesis, The previous shaft that was worn also killed the gear that it goes into, and now the new spline has a 1/4" of good gear that is now also bad because it is so small it cannot do the work that is required.

All you need is a new spline -- you already have it -- and the output gear that it goes into. With new splines on the output gear, and longer splines on the shaft itself, you should be good to go, and no other modifications needed. You do not need to overthink this one.

I'm not sure I'm understanding you, or if you weren't understanding me ( I have a habit of "Well, if it's completely clear to me--it MUST be to everyone else!" Non-Juvenile Egocentrism...

You area correct in what you started out with up top. Which is what I;m also looking for---the new driven gear (or "output gear"). This is the piece that I'm trying to find.

Where I'm lost is where you say I'm over-thinking it.

My end goal is to lengthen the front shaft and be able to couple it with a complete set of good condition splines on the output shaft. And of course do the chain while I have it torn down to that parts, and replace the actuator gear preemptively.

[DSSA]

Originally Posted by upallnight

To answe the OP's original question

Automatic, Standard Transmission & Transfer Case Rebuild Kits Cobra Transmission

BMW X5 - NV125 : , Cobra Transmission

That's the only place I could find them as well, but they want $390+ for the gear by itself.

With seeing many other places selling he same parts (with exception of the gear) for 50% less (or even more), I'm now searching for that last part.

[David.X5]

I looked, too, but did not find another source for the parts. There are several variants of the TC, so you need to figure out which one you have.

The NV125 was made by New Venture, which traces about 120+ years of US automotive history - owned at times by GM and Chrysler and making transmissions and TC for Jeep and GM products, including things like the "hydramatic transmission". The US plants have been shut down & off-shored.

The operations continue globally as part of Magna International. But, I haven't found one dribble of information on the Magna website. They seem to ignore the old NV products. Bottom line, limited sources for information and parts.

[srmmmm]

My driveshaft splines and TC output gear stripped at 136,000 miles. The local dealership installed a new driveshaft and a used TC that had 76,000 miles on it at the time. They would not warranty the work unless a new, BMW driveshaft was used. I've driven the vehicle another 139,000 miles since then without any problem. The service manager at the dealership assured me that none of the vehicles they had repaired had come back with the problem again because they were sure to really pack the spline joint with heavy grease. I have to admit, the original one was bone dry and had literally rusted away badly when it failed.

2002 X5 3.0 275,500 miles
2004 325i 119,500 miles

[David.X5]

It's funny you mention the grease. When I was putting mine back together I thought it would be pretty easy to retrofit a zerk fitting to allow periodic re-greasing. Sounds like an even better idea now.

[squidzilla]

Originally Posted by srmmmm

My driveshaft splines and TC output gear stripped at 136,000 miles. The local dealership installed a new driveshaft and a used TC that had 76,000 miles on it at the time. They would not warranty the work unless a new, BMW driveshaft was used. I've driven the vehicle another 139,000 miles since then without any problem. The service manager at the dealership assured me that none of the vehicles they had repaired had come back with the problem again because they were sure to really pack the spline joint with heavy grease. I have to admit, the original one was bone dry and had literally rusted away badly when it failed.

2002 X5 3.0 275,500 miles
2004 325i 119,500 miles

So it sounds like it would be a good idea to remove the drive shaft on mine and repack thoroughly with heavy grease.