2006 X5 - Drive Train Issue - Suggestions

[loungesurfer]

Hi all,

I'm looking for suggestions on what to do with my 2006 X5 that has a drive train issue.

Background:

- 2006 X5 4.4L with 100K+ miles - needs tires and other minor repairs.
- Diagnosed with stripped splines on front drive shaft and transfer case. Done by a local independent European car shop. Recommended replacing front drive shaft and using a transfer case spline repair kit at a cost of $2,200.
- I installed the "supposed" fix of a drive shaft with longer splines - did not fix the issue - already replaced front flex disk - huge front end clunk continues when driving forward - does not occur in reverse.
- Car's value in Southern California is $6K (maybe) - still owe over $10K and one month behind in payments due to unemployment.
- I'm not sure I would attempt removing the transfer case.

As I see it I have the following options
- Spend $2,200+ to repair it.
- Volunteer repossession

Any other thoughts?

Thanks, Denys

[wpoll]

If you replaced the front drive shaft already, that raises a couple of questions: -

1. Were the splines torn up on the old shaft and did the output splines seem damaged?

2. The total cost of repair should only be the t'fer case minus the driveshaft now?

Front drive shaft spline failure is supposed to be pretty rare on facelift models, even though the A/C drain is still directly above the spline joint. Maybe if you use you A/C a lot it can cause this failure.

Get a buddy that can help you get the t'fer case out - reducing the labour costs will bring the total repair cost down significantly.

Assuming the clunk is the t'fer case splines - which it sounds like it may not be but I can't think what else it would be, other than a failing CV joint or diff. Did the problem present itself suddenly of get worse over time?

Ok, that was three questions.

[loungesurfer]

Reply to wpoll

Thanks and good questions - responses below

1. Were the splines torn up on the old shaft and did the output splines seem damaged?

- I didn't think they were that bad, but I didn't have anything to gauge them by. The new "longer" splined front drive shaft went in easy and seemed to be tight fitting with the splines on the output shaft. However, once I drove it it made the same noise within the same amount of time/distance!

2. The total cost of repair should only be the t'fer case minus the driveshaft now?

- Correct

The independent garage diagnosed the problem by - their exact words:

- Road tested for noise
- Raised car and inspected drive train components
- Drive while on hoist and loaded drive train
- Found front drive shaft splines stripped in transfer case

- Recommendation: replace front drive shaft and rebuild transfer case - $2,200.

Right now I'm considering removing transfer case and getting it repaired/rebuilt or swapped. Just not cheap. I've found some YouTube videos on removing it, but still concerned I'll get into it and run into a issue - special tool required, etc.

Any suggestions appreciated and thanks again,
Denys

[Joshdub]

Does the sound persist with the car in rwd only? I think all you need to do is unplug the servo motor on the tcase to disable the awd.

[williamx5]

Originally Posted by Joshdub

Does the sound persist with the car in rwd only? I think all you need to do is unplug the servo motor on the tcase to disable the awd.

Good day!!

You beat me to this one!! As far as warnings and concerns, I don't think there are any other than the vehicle telling you that your servo motor for the T-case is disconnected... Which you already know...

Now, I got my 4.6is with a bad front driveshaft... I figured it took out the T-case too... It didn't... WHY?? Because it was the longer version that was made from cheaper, weaker metal than the T-case... I pulled a completely chewed up and nearly round driveshaft from the T-case to find the splines in the T-case nearly perfect... I personally can't explain it!! I think the drive shaft was made from aluminum...

Anyway, I think the new extended shaft should have fixed the issue, even for a short time... Months...... Maybe a year or so... Something else is going on... I did have an 02 that would pop if I used some of the available HP... Taking off granny slow from a light was just fine... I replaced the chain in the T-case and all was well again...

Not sure on this one... Will ponder it a while more...

Good luck!!

Cheers!!

[loungesurfer]

Originally Posted by williamx5

Good day!!

You beat me to this one!! As far as warnings and concerns, I don't think there are any other than the vehicle telling you that your servo motor for the T-case is disconnected... Which you already know...

Now, I got my 4.6is with a bad front driveshaft... I figured it took out the T-case too... It didn't... WHY?? Because it was the longer version that was made from cheaper, weaker metal than the T-case... I pulled a completely chewed up and nearly round driveshaft from the T-case to find the splines in the T-case nearly perfect... I personally can't explain it!! I think the drive shaft was made from aluminum...

Anyway, I think the new extended shaft should have fixed the issue, even for a short time... Months...... Maybe a year or so... Something else is going on... I did have an 02 that would pop if I used some of the available HP... Taking off granny slow from a light was just fine... I replaced the chain in the T-case and all was well again...

Not sure on this one... Will ponder it a while more...

Good luck!!

Cheers!!

Response to WilliamX5

Thanks for sharing. I'll likely pull the "longer" front drive shaft sometime in the future. For now it's just a sunk cost and I'll stick with RWD only. I might pull the servo motor to replace the internal gear. I doubt that's the issue cause I'm not getting the same warning lights or clicking noise. But it's an easy enough fix I can do.

Thanks again, Denys

[lo_jack]

Just to clarify, you are driving it in RWD only with the power to the transfercase motor pulled but the front driveshaft still in...and it works?

[loungesurfer]

Originally Posted by lo_jack

Just to clarify, you are driving it in RWD only with the power to the transfercase motor pulled but the front driveshaft still in...and it works?

Yes, correct - transfer case servo motor plug disconnected and front drive shaft still in place. All seems to be fine. The only warning light on is the triangle 4X4 light.

Not sure if you have a concern with this solution or just curious. If there's a potential issue with this, please share.

Thanks, Denys

[wpoll]

Given the info. you have provided, I can think of only two scenarios - either the output shaft splines on the t'case are totally munted and the output shaft needs to be replaced or the fault is actually in the t'case itself - worn drive chain most likely.

You'll need to source non-BMW parts to repair the t'case (if that's the fix) as BMW only sell complete t'case assemblies. I don't much for the ATC500 t'case except for chains either....

I guess it's also possible the front diff has shat itself but that's pretty rare - about as rare as a facelift E53 chewing out the front drive shaft splines.

Did the indy pull any codes by any chance?

[loungesurfer]

Response & Question

Wpoll - I thought the "chain" system in the transfer case was eliminated by 2006. If that's not the case I too would think it's either the output shaft splines or the chain.

JoshDub - your suggestion of disconnecting the servo motor worked perfectly! The only warning light is the 4X4 light. Now I have a RWD X5 - at least until I can gather the cash to fix it or sell it. Thanks for the suggestion!

All - My questions now that I've disconnected the servo motor are there any issues with leaving it disconnected?

Based on my reading it may affect ABS and/or DSC. I live in So Cali so there little likelihood of venturing out in sand, snow or ice! Our X5 is really to haul our Great Danes.

Thanks to all for the help!