Help - New Front driveshaft not going in

[Henn28]

Originally Posted by ewebby

I ended up giving up trying to get it into my old transfer case, I bought a new shaft and rebuilt transfer case from https://www.tcbmwx5.com/
check your splines, if they look like mine above, you need a transfer case. 4 hours of filing did not work due to the first inch of splines were half broken off and the torque kinda bent them, no way to get it in. 4 days of trying and figured with 260k prob worth it to get a rebuilt. Plan on keeping car for another 5 years so will see.

Thanks for this lead. I recently welded new splines on my driveshaft and fit another 1/2” into the t-case, but at 155k I suspect my t-case has at least one foot in the departure lounge. Let us know how your experience with the rebuilt one goes please.

[andrewwynn]

I had a customer drive into a parking curb at 30mph; it broke his front drive prop free which flopped around and put a hole in his transmission pan breaking off a couple pan bolts as well.

It is an xdrive so I just removed the front prop completely so he could drive RWD until I replaced the prop (and a outside the box shop fixed the busted t pan using rtv and through bolts to replace the bolt bosses that broke off).

Skip ahead a few months and we discover the impact damaged the front seal on the TC so the oil leaked out and it burned up the TC.

I found a complete TC for about $550 reasonable miles and with a warranty so that was 30,000 miles ago

[x5Alpine]

When replacing the front driveshaft with a longer version it is far easier to just move the front Diff forward a bit rather than the t case.

[ewebby]

i ended up getting new shaft and rebuilt TC. All works well