X5 Transfer Case Actuator Motor Gear Replacement

[richardb]

Originally Posted by AV8R4AA

Is this repair a recommended procedure, even if you don't have any
dash lights?
I ask because I am nearing 100K miles.
No dash lights at all.
I have a 2004 X5 4.4i

I think most people usually wait until they start experiencing symptoms of the failing gear. But considering the gear is $11 it wouldn't hurt to order one and keep it in your tool box for a rainy day!

[richardb]

Originally Posted by AV8R4AA

Is this repair a recommended procedure, even if you don't have any
dash lights?
I ask because I am nearing 100K miles.
No dash lights at all.
I have a 2004 X5 4.4i

I don't think many people do the repair until it becomes a problem. But for the $11 or whatever the gear costs on Amazon, you may as well order one and keep it in your tool box for a rainy day!

[AV8R4AA]

I went ahead and replaced the sprocket.
The original unit was a little bit worn.
Every once in a while I would get a rumbling sound while making
right hand slow turns. After replacing the sprocket, the rumbling has stopped.
It was an easy job.

[iansanderson]

I replaced mine preventatively at 130K, and the original gear looked brand new! What a waste of time.

Only explanation I can give is that my car probably never saw snow since it was from New Mexico, so the gear rarely turned. Original actuator dated 04.

[dkl]

Originally Posted by iansanderson

I replaced mine preventatively at 130K, and the original gear looked brand new! What a waste of time.

Only explanation I can give is that my car probably never saw snow since it was from New Mexico, so the gear rarely turned. Original actuator dated 04.

So my California car should last past 260K???

[iansanderson]

I'm thinking the gear turns mainly when DXC detects a slipping moment during acceleration, thus turning the gear which transfers additional power needed to the front or rear differential.

The other scenario is when the vehicle is going faster than 112 MPH, and the transfer case changes to rear drive only, and needs to turn the gear.

I have to assume if you rarely experience any of the above situations, the gear remains stationary, thus not prone to failure.

[JCL]

Originally Posted by iansanderson

I'm thinking the gear turns mainly when DXC detects a slipping moment during acceleration, thus turning the gear which transfers additional power needed to the front or rear differential.

The other scenario is when the vehicle is going faster than 112 MPH, and the transfer case changes to rear drive only, and needs to turn the gear.

I have to assume if you rarely experience any of the above situations, the gear remains stationary, thus not prone to failure.

While x drive (2004 onwards for X5, all X3) is normally 60:40 torque split, it goes to full torque to the rear wheels in certain situations that you encounter regularly. One is low speed parking maneuvers, where there is a significant difference in wheel speed left to right, and very low torque applied.

[bcredliner]

Since the actuator gear normally lasts 100,000 miles or more and the gear is designed to wear properly with OE sprocket I would only replace with an OE gear. If I had one handy for the next time I wouldn't know where it was if I ever needed it and if it held up for 100,000 miles it would be at least 10 years before I would need to look. I have never heard the E53 becomes rear wheel drive at any speed--fact check. I don't know about yours but mine is 60-40 all the time.

[cn90]

Thanks for the DIY.

I am at 120K miles and have no problems on the snow (yet).
I wonder if I should "refresh" the gear by taking it out, turn it around 180 degrees or so, this way the "untouched" part of the plastic gear is now on the "active" side.

This has been done by a few people on different forums:

Transfer Case Actuator potential free fix! - Bimmerfest - BMW Forums

[richardb]

For some reason the video isn't playing on the forum anymore? Just me or anyone else?

Here's a direct link in case: https://www.youtube.com/watch?v=UR7Vv5SQvDc