2002 x5 transfer case/front drive shaft problem

[tijanaw]

Just wanted to thank Tom for his assistance & very creative and affordable solution. We got stranded on 95N the night before thanksgiving the wife, kids and I. After towing back the X to the DC area, I heard from my mechanic on Monday telling me to basically replace the transfer case & drive shaft. In my case this would be the 2nd time around. Long story short, I called Tom and shipped him my drive shaft which he repaired and mailed right back. I picked up the X yesterday and couldn't be happier about the outcome.
Good solution if you have an older X & don't want to spend $2500 just in parts.

[elric75]

I'll also chime in and says thanks to Tom for this solution. My 2000 X5 4.4 with only 89k miles shredded the driveshaft splines just like in the pics, and his solution worked for me and saved money vs. other options. The only issue I ran into was finding a local shop that was willing to go with this option. The first shop refused, but a second one was fine with it and indeed the owner later told me that it appeared to be an interesting and very fine solution to this problem.

[GNP]

Thanks for all the info in this thread!

Wish I had found it before I had an independent transmission shop replace the transfer case and the front drive shaft.

I have a 2001 4.4i with 155K. Stopped at a traffic light and when it turned green, there was a horrendous grinding sound and and the X5 rolled backwards while still in drive. No warning sounds, no warning lights, or any kind of warning whatsoever. X5 was driving normally before failure.

I don't know if there is any way you can do preventive maintenance on this, but it does leave you stranded without any warning.

Thanks for the website below. Great prices!

Transfer Case Express, Inc. · New, rebuilt transfer cases ( transfercase ). Lowest prices. In California, world-wide delivery

[J.Belknap]

This thread should be a sticky.

[Turbo_BM]

+1 seems like all e53 owners will know tom at some point.


Sent from the Thunderdome.

[X5only]

I have a 2005 4.4. Does this issue happen on these vehicles too? I'd like to inspect the drive shaft myself but would like to know before getting started.

[giodog2000]

[X5only]

Originally Posted by X5only

I have a 2005 4.4. Does this issue happen on these vehicles too? I'd like to inspect the drive shaft myself but would like to know before getting started.

Asking because 04+ have Xdrive instead of the old regular 40/60 split transfer case. Are the diffs ends exactly the same or the engineering flaw causing this issue was addressed in later year models?

[X5only]

Originally Posted by X5only

Asking because 04+ have Xdrive instead of the old regular 40/60 split transfer case. Are the diffs ends exactly the same or the engineering flaw causing this issue was addressed in later year models?

Ok, found the answer to my query in an old thread. Weasel pointed out in that thread that the shredded spline issue does not affect Xdrive
http://www.xoutpost.com/bmw-sav-forums/x5-e53-forum/63004-transfer-case-removal-pictures-6.html

"The older one can have the chain slack problem like this thread, and the front output shaft splines can strip on some of them as well. The x-drive is not going to have the output shaft splines problems and is not going to have the chain slack problems... because all the abuse gets thrown to the clutch pack, which is what wears on them causing replacement costs.
Pretty much either one is just as likely to get worn to the point of repalcement over the years. But that is with anything with a transfer case. I've repalced them on fords, chevys, dodges, jeeps, etc. Unavoidable costs of having a 4 wheel drive vehicle."

[jwilb4]

Here's the Central American solution to the "short" front drive shaft problem... can't vouch for how sound this is mechanically but its a pretty simple idea....