I need a Transfer Case! Or Fix What I Have...

[tempest411]

Hello,


It looks like I am unable to obtain a new front drive sprocket piece for the LWX500 in my '03. Cobra Transmissions has listed them as in stock for years, but it turns out they were all mis-packaged. Most other places think I'm speaking Chinese when I ask them about BMW transfer case parts. Mine isn't stripped, but a person more observant than me pointed out that the splines were worn while I had it apart to replace the chain and seals. My options are to obtain an NV125, either used or rebuilt, or try Loctite 660 on what I've got. I'm less worried about the Loctite working than I am about what I'm going to do if I ever need to get it apart again. I'd really like to keep the LWX, as it has larger bearings, which is always nice in drive train stuff...Rebuilding an NV125 myself may be the best option. I can source a new front drive sprocket without too much trouble if need be, and they come apart so easily. I can't see how it would be worth paying anyone $1500+ for one that has been rebuilt by a shop. What would you do?


Thank you for your suggestions.


Oh, by the way, what is the black thing around the rear axle output on this NV125? I don't have it on my LWX, and I haven't seen it on all NV125s.

[andrewwynn]

Is another option getting the longer version of the front prop shaft? It's the typical fix somebody does after they do strip their spline.

Heat will release loctite should you go that route.

[nahvkolaj]

As andrew said look into the front prop shaft with longer splines. Snap a pic of the wear on your output shaft splines.

The mass on the NV125 is a vibration damper.

[andrewwynn]

If you want to DIY rebuild maybe you can find a donor pay from a junkyard? Too bad I didn't think of it I had a TC that internal failed prob had a perfect output shaft.

[80stech]

A lot of this was covered in OPs previous thread. No idea why a new one was started.

[tempest411]

Originally Posted by 80stech

A lot of this was covered in OPs previous thread. No idea why a new one was started.

A new thread was started because the work is going a very different direction than originally expected. Having to choose between bodging together a worn transfer case and finding another case entirely is very different from simply changing the seals and chain. I was actually hoping someone would chime in with a source for the output shaft for my LWX500. Wishful thinking I guess.

[tempest411]

Originally Posted by nahvkolaj

As andrew said look into the front prop shaft with longer splines. Snap a pic of the wear on your output shaft splines.

The mass on the NV125 is a vibration damper.

Here's a couple pictures. One is of what it should look like, and the other is of what mine looks like. I've been using the extended front driveshaft for the last five years. It was installed when the transmission came out for a rebuild. The wear is down the entire length of the splines, except for the last 2-4mm. I kind of wonder if my wife's 'unique' driving style is partially to blame. She treats the accelerator as an on-off means of moving a vehicle. I wonder if the constant loading and unloading of the drive train hammers on these splines, accelerating wear.

[wpoll]

Originally Posted by tempest411

... I kind of wonder if my wife's 'unique' driving style is partially to blame. ...

She's not "unique" in driving like that!

Originally Posted by tempest411

... I wonder if the constant loading and unloading of the drive train hammers on these splines, accelerating wear. ...

Probably....

[jbfrancis3]

The Cobra issue is frustrating. The front driveshaft has a flex joint ("giubo") which should have been the primary recipient of the abuse but the spline damage is clear as day so who knows.

I didn't appreciate there was even an LWX500 (I read it was for short period of time) until now. There's an ebay seller showing output shaft for only NV125 and cautions it doesn't work with LWX500.

However, they're clearly knowledgeable so it may be a good lead:
https://www.ebay.com/itm/14514954999...UaAgaOEALw_wcB

[EODguy]

Originally Posted by tempest411

A new thread was started because the work is going a very different direction than originally expected. Having to choose between bodging together a worn transfer case and finding another case entirely is very different from simply changing the seals and chain. I was actually hoping someone would chime in with a source for the output shaft for my LWX500. Wishful thinking I guess.

I don't know if it's still done, but many high schools and tech schools will machine a part for the cost of materials and fees as a graded problem for the students.....

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