Kiwi E53 3.0D ABS, Brake & ABS Trifecta Warning Lights

[fredm8]

Hi All,
I know this has been posted previously, but I can’t seem to find the thread & solutions proposed….

I have an 09/2006 E53 X5 3.0D that is displaying the dreaded trifecta of warning lights. - 4x4, ABS & Brake Failure.

Diagnostic codes identified are:
4F7A - Signal from Transfer Case Faulty
5F3A - Transfer Case Internal

Transfer Box (VGS)
5463 - Mechanism Faulty
55C4 - No Message from DSC

Car is only driving in rear wheel drive, no 4WD.

I’ve just replaced the ATC unit with a new one, and it hasn’t resolved the problem.
The mechanic that did the service repair work suggested that the ATC unit wasn’t the culprit, as the mechanism worked but wouldn’t reach far enough into the transmission to engage the 4WD.

Car has done 337000KM (mine since 2008 at 28000km).

What does the forum suggest as the next triage step to identity the fault and rectify please.

[wpoll]

Originally Posted by fredm8

... The mechanic that did the service repair work suggested that the ATC unit wasn’t the culprit, as the mechanism worked but wouldn’t reach far enough into the transmission to engage the 4WD. ...

What?

Sounds like this "mechanic" doesn't know what he's talking about....

Was the entire transfer case changed or just the electric actuator on the side of the transfer case?

In either case, the errors would likely need to be cleared after the repair.

[fredm8]

New ATC unit installed yesterday to replace original unit (Which had been rebuilt at around 200,00km)

Yes. The error codes were all cleared & reset once the ATC was replaced.

Warning lights on dashboard remain active. (I’m sourcing an OBD unit to validate which error codes are now active.

[wpoll]

Originally Posted by fredm8

New ATC unit installed yesterday to replace original unit (Which had been rebuilt at around 200,00km)

Yes. The error codes were all cleared & reset once the ATC was replaced.

Warning lights on dashboard remain active. (I’m sourcing an OBD unit to validate which error codes are now active.

By ATC, do you mean the entire ATC500 transfer case, including gearing, chain, clutch packs etc.?

And if so, was the actuator unit also swapped out or is the original actuator unit installed on the new transfer case?

Sorry to ask again but I'm not clear, since "ATC" could mean Air Traffic Control for all I know!

For reference, here's an ATC500 WITH the actuator attached...



Here's just the actuator unit...

[fredm8]

Hi Wayne etal.

I obtained a new Transfer Case Actuator control unit, and the mechanic swapped it for the old one (just the part with the plastic gears :-) - your second picture.) I *didnt* swap out the entire transfer case.

OBD Reader scan today and clear all the error codes.

Subsequent scan provides the following errors
54C4/present VTG Calibration Faulty.
5F3A/not present DSC: Transfer Case Malfunction.
4F7A/not present EGS: Signal from transfer box is faulty
539E/not present VTG: 539E Transfer Case malfunction.

What is required and the process to calibrate the new Transfer Case Actuator ?

[fredm8]

Apologies for my lack of technical detail to describe exactly the parts.
I’m working off an iPad, which doesn’t easily allow my to drop images into the forum editing screen.

[wpoll]

Originally Posted by fredm8

Hi Wayne etal.

I obtained a new Transfer Case Actuator control unit, and the mechanic swapped it for the old one (just the part with the plastic gears :-) - your second picture.) I *didnt* swap out the entire transfer case.

OBD Reader scan today and clear all the error codes.

Subsequent scan provides the following errors
54C4/present VTG Calibration Faulty.
5F3A/not present DSC: Transfer Case Malfunction.
4F7A/not present EGS: Signal from transfer box is faulty
539E/not present VTG: 539E Transfer Case malfunction.

What is required and the process to calibrate the new Transfer Case Actuator ?

Ah-ha! All good.

So.... you'll likely need either DIS (v44 or newer) or ISTA-D - both BMW applications that run on laptops (or a desktop!).

It's also possible that a Foxwell scanner might be able to do it (not 100% certain) but INPA and BMW Scanner (PASoft) definitely won't.

Might be easier to take it into a BMW dealer and ask them to do it.

[wpoll]

Unless you aren't too far from Dunedin!

[fredm8]

Mangawhai Heads…. A little far for quick calibration visit…

[X5chemist]

A Foxwell scanner can do a transfer case adaptation. After replacing a failed gear with a much carbon one, I did an adaptation. I would tell the difference right away. All the trifecta lights disappeared too.