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  #1  
Old 06-11-2016, 04:22 PM
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X5 Transfer Case Actuator Motor Gear Replacement

I finally uploaded the DIY video for repairing the transfer case actuator with a new gear. I completed the repair in December 2015 and we have had zero issues since!

The BMW service centers will tell you that the entire transfer case needs to be replaced at a cost of over $4,000 simply because they do not replace the actuator motor or the plastic gear inside it.

We also did a drain and fill of the transfer case with fresh BMW fluid after replacing the gear. Hope this helps someone get back on the road!

https://www.youtube.com/watch?v=UR7Vv5SQvDc


Good luck!

Last edited by richardb; 03-15-2017 at 08:54 AM.
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Old 06-11-2016, 06:50 PM
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Great video
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Old 06-12-2016, 03:45 AM
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Re Brand.

On ebay, there are some sellers, but who do you guys use?
In other words, who sells the best quality plastic gear?
Brand Name?
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Old 06-12-2016, 03:47 AM
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A vendor sells Aluminum gear, interesting...

Transfer Case Motor Gear Repair Kit BMW E83 X3 E53 X5 E71 X6 27107566296 G019
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Old 06-12-2016, 09:52 AM
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I've also seen a Kevlar reinforced gear and a carbon fiber gear I believe
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Old 06-13-2016, 12:27 PM
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Quote:
Originally Posted by cn90 View Post
Re Brand.

On ebay, there are some sellers, but who do you guys use?
In other words, who sells the best quality plastic gear?
Brand Name?
I bought the carbon/kevlar plastic gear on Amazon for $11 shipped. The weak factory gear lasted over 100k, so I think the updated plastic gear would last at least that long. I think the aluminum gear is a bit much.
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Old 06-13-2016, 01:12 PM
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I got the carbon/kevlar reinforced nylon via Amazon, as well. Seems to be working fine, been in there well over 25k miles .....
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Old 06-13-2016, 01:16 PM
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I would be concerned with the aluminum gear causing wear on the worm screw. Then you would need to replace the entire actuator.
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2003 X5 4.6is Estoril Blue
2005 Infiniti G35X
1972 Datsun 240Z
1991 Isuzu Impulse XS Sold
1972 Fiat 850 Spyder Donated
1972 Datsun 240Z Sold
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Last edited by jcp240z; 06-14-2016 at 11:07 AM.
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Old 06-14-2016, 06:59 AM
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Quote:
Originally Posted by jcp240z View Post
I would be concerned with the aluminum gear causing wear on he worm screw. Then you would need to replace the entire actuator.
^This...
I was thinking the same thing;
I'm not sure what the screw is made of,
but I'd rather it destroy a plastic gear after seven or so years of use,
and just replace that.

Aluminum is usually a soft metal, maybe someone who has tried one can chime in after a few years of use to let us know how the actuator has stood up over time with an aluminum gear.
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Old 06-14-2016, 02:56 PM
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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
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