2002 x5 transfer case/front drive shaft problem

[dville]

My transfer case chain came in the mail today....$146 via PayPal.
Gonna try to replace it this weekend. (wish me luck).

transfercase dot com wanted $1100 for a rebuilt unit for the X5....

If I fail, then I am going 2WD conversion by lengthening the rear driveshaft....!!!

[amacman]

i wonder if it would be possible to fit a spacer at flexdisc to push splines in further .

[dville]

Working on removal here--->
http://www.xoutpost.com/bmw-sav-foru...-pictures.html

[ttzcar]

I wanted to let you guys know I went with Tom's (RaceMalibu) extended shaft and it worked perfectly. Also I didn't have to completely remove the transfer case, I unscrewed the external torx screws out about 95% and slid the transfer case out and that gave me enough room to get the new shaft in. After I put the new shaft into the transfer case, I installed the flex joint afterwards. It made things really easy not needing a helper to align and put the case back on. I ended up using a 10mm ratchet wrench, because of the tight fit, like dville suggested and that worked too. On some of those case bolts you can't even get a socket in there. (However I did end up stripping one up top and because of the tight squeeze I was limited on removal/extracting options so I ended up having to grind off the head. The case isn't threaded.) Saved myself over $1,000. And as Tom mentions now it's stronger than before, utilizing more of a percentage of the good splines still left in the case. Thanks Tom.

[racemalibu572]

Originally Posted by dville

You do NOT have to take of transfer case to remove front driveshaft.
I just did it (I have BMW TIS CD).
The reason the splines on the transfer case have so much extra room is so you can remove the front driveshaft.
You simply remove the front stiffener plate, undo the bolts at the front driveshaft flexdisk, then use a crowbar and slide the shaft backwards until the flexdisc can slide out (it has a centering device that sticks into the flange on the front differential preventing it from just dropping out).

If you lengthen the front driveshaft, then you will HAVE to remove the transfer case to take out the front driveshaft, since you will not be able to slide the shaft backwards to clear the flexdisk.

I see that now, due to living in the middle of the "rust belt", it appeared that the pilot flange and the shaft were one piece. Working on it at 3am didn't help either, I just wanted to get it apart. The first prototype I put in my own car was a little longer than the new production pieces, so I had to remove the case. As ttzcar just posted, the new extended shaft goes in with out having to completely remove the case. I would like to give a big thanks to Joe and Jimmy for being so patient during getting these made, we ran into a few bumps but it looks like smooth sailing ahead. I have some pictures to upload of the new shafts, I'll get them up shortly.

[racemalibu572]

Here are some pictures of the new shaft repair components.
These are the new one piece blanks I had made.


This will give you a good idea of what the damaged shaft looks like and the amount of good spline that gets used.


The press fit step is machined to fit the i.d. of each shaft repaired. Runout is checked as it's being machined as well as when it is being welded in.


Here is the first finished shaft.


I haven't ordered any more blanks yet to keep in stock, but if you need one done they're only 4 days for me to get, so I can have them by the time I receive your core. If I get enough interest in these I plan on having some finished shafts in stock. If your interested in having one done please call me at 262-749-0689 or e-mail me at [email protected]. Thanks again, Tom Gottschalk.

[Rooster]

Wow Tom, nice work. My X just got diagnosed with a bad transfer case. Mechanic is shopping around for a replacement. Is this shaft the only part that needs to be replaced? Remanufactured transfer case is $1300.

btw, very disappointed in this. only 95K miles on this thing and it stranded my wife and 1 yr old daughter on a freeway overpass.

[Werewolf]

Originally Posted by Rooster

Wow Tom, nice work. My X just got diagnosed with a bad transfer case. Mechanic is shopping around for a replacement. Is this shaft the only part that needs to be replaced? Remanufactured transfer case is $1300.

btw, very disappointed in this. only 95K miles on this thing and it stranded my wife and 1 yr old daughter on a freeway overpass.

I don't blame you. Failures are to be expected but drivetrain failures are the least acceptable ones.

[Rooster]

Originally Posted by Werewolf

I don't blame you. Failures are to be expected but drivetrain failures are the least acceptable ones.

yep, and i just got a notice about a settlement in a class action lawsuit regarding the subframe design flaw in my 330i. love my bimmers, but damn this forces me to think twice.

[Werewolf]

Me too. I love BMWs and we've had them in the family for a long time. But the newer ones (mid 90s and on) IMHO went into mechanical designs and parts which were meant to go bad / obsolete earlier than acceptable.

I love the x5 but the awd system has never been a focus for the company. It bothers me but doesn't surprise me that the transfer case was under-engineered.

For the record, I think all premium cars should get 200-300k out of the block and 150-200 out of the tranny with normal driving conditions.